Information injection-pump assembly
ZEXEL
106691-1760
1066911760
ISUZU
1156002501
1156002501

Rating:
Service parts 106691-1760 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-008-0
12.
Open Pre:MPa(Kqf/cm2)
22.1{225}
15.
NOZZLE SET
Include in #1:
106691-1760
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106691-1760
1066911760
ISUZU
1156002501
1156002501
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
7.7
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
119.4
115.8
123
Max. variation between cylinders
%
0
-3
3
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.7
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
116.2
112.8
119.6
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
5.5+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
22.5
19.3
25.7
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
10++
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
125
125
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Injection quantity adjustment_05
Adjusting point
E
Rack position
7.7+0.2
Pump speed
r/min
420
420
420
Average injection quantity
mm3/st.
109
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)Set the load lever's stop position so that R = aa (N = 0).
(3)Excess fuel setting for starting: SXL
----------
DL=5.5-0.5mm aa=5mm SXL=7.7+0.2mm
----------
----------
DL=5.5-0.5mm aa=5mm SXL=7.7+0.2mm
----------
0000000901

F:Full load
I:Idle
S:Stop
----------
----------
a=6.5deg+-5deg b=8deg+-5deg c=29deg+-3deg
----------
----------
a=6.5deg+-5deg b=8deg+-5deg c=29deg+-3deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=275r/min Ra=5.5mm
----------
----------
N1=275r/min Ra=5.5mm
----------
Information:
General Recommendations and Contamination Control Guidelines for Fuels
Follow all applicable industry standards and all applicable governmental, environmental, and safety guidelines, practices, regulations, and mandates.Note: These general recommendations and guidelines concerning maintenance and care of fuel and fuel storage systems are not intended to be all inclusive. Discuss proper fuel safety and health, handling, and maintenance practices with your fuel supplier. Use of these general recommendations and guidelines does not lessen the engine owners and/or fuel supplier responsibility to follow all industry standard practices for fuel storage and for fuel handling.Note: Where recommendations for draining water and/or sediment and/or debris are stated, dispose of this waste according to all applicable regulations and mandates.Note: Caterpillar filters are designed and built to provide optimal performance and protection of the fuel system components.Clean fuels, as detailed below, are strongly recommended to allow optimal performance and durability of the fuel systems and to reduce power loss, failures, and related down time of engines.Fuels of “ISO 18/16/13” cleanliness levels or cleaner as dispensed into the engine or machine fuel tank should be used. Reduced power, failures and related downtime can result if clean fuels are not used. Fuels of “ISO 18/16/13” are particularly important for new fuel system designs such as Common Rail injection systems and unit injection systems. These new injection system designs utilize higher fuel pressures and are designed with tight clearances between moving parts to meet required stringent emissions regulations. Peak injection pressures in current fuel injection systems may exceed 30,000 psi. Clearances in these systems are less than 5 µm. As a result, particle contaminants as small as 4 µm can cause scoring and scratching of internal pump and injector surfaces and of injector nozzles.Water in the fuel causes cavitation, corrosion of fuel system parts, and provides an environment where microbial growth in the fuel can flourish. Other sources of fuel contamination are soaps, gels, or other compounds that may result from undesirable chemical interactions in the fuels. Gels and other insoluble compounds can also form in biodiesel fuel at low temperatures or if biodiesel is stored for extended periods. An indication of microbial contamination, detrimental fuel additives interactions, or cold temperature gel is very rapid filter plugging of bulk fuel filters or machine fuel filters.To reduce downtime due to contamination, follow these fuel maintenance guidelines in addition to the recommendations given in the "Contamination Control" Chapter in this Special Publication:
Use high-quality fuels per recommended and required specifications (refer to the “Fuel” chapter in this Special Publication).
Do not add new engine oil, waste engine oil or any oil product to the fuel unless the engine is designed and certified to burn diesel engine oil (for example Caterpillar ORS designed for large engines). Engine oils may raise the sulfur level of the fuel and may cause fouling of the fuel system and loss of performance. Engine oils in fuels can also reduce the maintenance intervals of aftertreatment devices in Tier 4 machines.
Use recommended Cat filtration products, including Cat Advanced Efficiency Fuel
Follow all applicable industry standards and all applicable governmental, environmental, and safety guidelines, practices, regulations, and mandates.Note: These general recommendations and guidelines concerning maintenance and care of fuel and fuel storage systems are not intended to be all inclusive. Discuss proper fuel safety and health, handling, and maintenance practices with your fuel supplier. Use of these general recommendations and guidelines does not lessen the engine owners and/or fuel supplier responsibility to follow all industry standard practices for fuel storage and for fuel handling.Note: Where recommendations for draining water and/or sediment and/or debris are stated, dispose of this waste according to all applicable regulations and mandates.Note: Caterpillar filters are designed and built to provide optimal performance and protection of the fuel system components.Clean fuels, as detailed below, are strongly recommended to allow optimal performance and durability of the fuel systems and to reduce power loss, failures, and related down time of engines.Fuels of “ISO 18/16/13” cleanliness levels or cleaner as dispensed into the engine or machine fuel tank should be used. Reduced power, failures and related downtime can result if clean fuels are not used. Fuels of “ISO 18/16/13” are particularly important for new fuel system designs such as Common Rail injection systems and unit injection systems. These new injection system designs utilize higher fuel pressures and are designed with tight clearances between moving parts to meet required stringent emissions regulations. Peak injection pressures in current fuel injection systems may exceed 30,000 psi. Clearances in these systems are less than 5 µm. As a result, particle contaminants as small as 4 µm can cause scoring and scratching of internal pump and injector surfaces and of injector nozzles.Water in the fuel causes cavitation, corrosion of fuel system parts, and provides an environment where microbial growth in the fuel can flourish. Other sources of fuel contamination are soaps, gels, or other compounds that may result from undesirable chemical interactions in the fuels. Gels and other insoluble compounds can also form in biodiesel fuel at low temperatures or if biodiesel is stored for extended periods. An indication of microbial contamination, detrimental fuel additives interactions, or cold temperature gel is very rapid filter plugging of bulk fuel filters or machine fuel filters.To reduce downtime due to contamination, follow these fuel maintenance guidelines in addition to the recommendations given in the "Contamination Control" Chapter in this Special Publication:
Use high-quality fuels per recommended and required specifications (refer to the “Fuel” chapter in this Special Publication).
Do not add new engine oil, waste engine oil or any oil product to the fuel unless the engine is designed and certified to burn diesel engine oil (for example Caterpillar ORS designed for large engines). Engine oils may raise the sulfur level of the fuel and may cause fouling of the fuel system and loss of performance. Engine oils in fuels can also reduce the maintenance intervals of aftertreatment devices in Tier 4 machines.
Use recommended Cat filtration products, including Cat Advanced Efficiency Fuel