Information injection-pump assembly
ZEXEL
106991-1014
1069911014
ISUZU
1156024984
1156024984
Rating:
Service parts 106991-1014 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-204-1
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.1{225}
15.
NOZZLE SET
Include in #1:
106991-1014
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106991-1014
1069911014
ISUZU
1156024984
1156024984
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 (drive side)
134424-4020
Overflow valve opening pressure (drive side)
kPa
255
221
289
Overflow valve opening pressure (drive side)
kgf/cm2
2.6
2.25
2.95
Overflow valve (governor side)
134424-2720
Overflow valve opening pressure (governor side)
kPa
255
221
289
Overflow valve opening pressure (governor side)
kgf/cm2
2.6
2.25
2.95
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
1-8-7-6-
5-4-3-10
-9-2
Pre-stroke
mm
4.2
4.17
4.23
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 27 26.75 27.25
Cal 1-8 deg. 27 26.75 27.25
Difference between angles 2
Cal 1-7 deg. 72 71.75 72.25
Cal 1-7 deg. 72 71.75 72.25
Difference between angles 3
Cal 1-6 deg. 99 98.75 99.25
Cal 1-6 deg. 99 98.75 99.25
Difference between angles 4
Cal 1-5 deg. 144 143.75 144.25
Cal 1-5 deg. 144 143.75 144.25
Difference between angles 5
Cal 1-4 deg. 171 170.75 171.25
Cal 1-4 deg. 171 170.75 171.25
Difference between angles 6
Cal 1-3 deg. 216 215.75 216.25
Cal 1-3 deg. 216 215.75 216.25
Difference between angles 7
Cal 1-10 deg. 243 242.75 243.25
Cal 1-10 deg. 243 242.75 243.25
Difference between angles 8
Cal 1-9 deg. 288 287.75 288.25
Cal 1-9 deg. 288 287.75 288.25
Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
8.1
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
104
102.5
105.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
104.1
102.1
106.1
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.6
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
109.6
107.6
111.6
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
4.8+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8.7
7.4
10
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Timer adjustment
Pump speed
r/min
600--
Advance angle
deg.
0
0
0
Load
4/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
550
Advance angle
deg.
0.3
Load
4/4
Timer adjustment_03
Pump speed
r/min
820+-30
Advance angle
deg.
2
1.5
2.5
Load
4/4
Timer adjustment_04
Pump speed
r/min
900
Advance angle
deg.
2
1.5
2.5
Load
3/4
Timer adjustment_05
Pump speed
r/min
1100
Advance angle
deg.
5.5
5
6
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Damper spring setting
----------
RT=0.8 TH=1.9mm
----------
----------
RT=0.8 TH=1.9mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=6deg+-5deg
----------
----------
a=6deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=32deg+-3deg
----------
----------
a=10deg+-5deg b=32deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=60deg+-5deg b=73deg+-5deg
----------
----------
a=60deg+-5deg b=73deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side)
(3)B.T.D.C.: aa (set timing)
(4)-
----------
aa=8deg
----------
a=(180deg)
----------
aa=8deg
----------
a=(180deg)
Information:
Above 16°C (60°F)
Consult the "Operation" (Operator's) Guide for before starting checks. 1. Turn on the scraper disconnect switch. 2. Move the scraper governor to just past ENGINE STOPPED detent. 3. Push in and turn the start switch to START. Release the switch when the engine starts.
After every 30 seconds of cranking, allow 2 minutes for the starting motor to cool.
4. If the engine oil pressure gauge doesn't register within 10 seconds, push the governor control to the ENGINE STOPPED position to stop the engine. Have corrections made.5. Keep the engine at low idle until the systems are warm.6. Watch all gauges and indicators for correct readings before moving the machine.16°C (60°F) to -12°C (10°F)
1. Follow the steps under "Above 16°C (60°F)."
If the engine does not start after two attempts, use starting fluid. This will prevent excessive battery drain and starting motor overheating.
2. Use starting fluid by pushing the button under the start switch, at 2 second intervals, while cranking the engine. See "Ether Aids" under "Cold Weather Starting Aids."-12°C (10°F) to -26°C (-15°F)
1. Follow the steps under "Above 16°C (60°F)."2. Coolant heaters are required.3. An external battery source may be required if the battery charge is not maintained. See "Boost Starting" under "Cold Weather Starting Aids."4. Starting fluid is required. See "Ether Aids" under "Cold Weather Starting Aids."Below -26°C (-15°F)
1. Follow the steps under "Above 16°C (60°F)."2. Coolant heaters are required.3. An external battery source may be required. See "Boost Starting" under "Cold Weather Starting Aids."4. Starting fluid is required. See "Ether Aids" under "Cold Weather Starting Aids."5. Special lubricants are required. Consult your Caterpillar dealer or refer to Caterpillar Form Number SEBU5338, "Operation, Lubrication and Maintenance Guide for Cold Weather Operation."Starting Aids
Winter Oils
The use of SAE10W viscosity oil in the compartments listed on the chart below will aid in cold weather starting.
Use SAE10W oil only in the temperature ranges indicated.
At lower than above temperatures consult your Caterpillar dealer or refer to the "Operation, Lubrication and Maintenance Guide for Cold Weather Operation," Caterpillar Form Number SEBU5338, for the correct lubricants to use.Ether Aids
Ether is a poison and is flammable.Use it only in well ventilated areas.Use it with care to avoid fires.Avoid breathing the ether vapors, or repeated contact of ether with skin.Do not use ether in environments above 90°C (200°F).
Ether is to be used for cold starting purposes only. Use ether only while cranking the engine. Use it sparingly. Excessive ether can cause piston and ring damage.
Push the button only while cranking the engine.A metered amount of starting fluid (ether) is released each time the button is pushed.After pushing the button, allow 2 seconds before pushing it again.Continue the use of starting fluid every 2 seconds after the engine starts, until it is running smoothly.Batteries
Keep batteries charged to a corrected specific gravity of 1.250 or above. Otherwise, an external electrical source may be required.Boost Starting
Do not allow cable ends to contact each other or the machine.Prevent sparks near the batteries. They could cause battery vapors (hydrogen) to explode.
When
Consult the "Operation" (Operator's) Guide for before starting checks. 1. Turn on the scraper disconnect switch. 2. Move the scraper governor to just past ENGINE STOPPED detent. 3. Push in and turn the start switch to START. Release the switch when the engine starts.
After every 30 seconds of cranking, allow 2 minutes for the starting motor to cool.
4. If the engine oil pressure gauge doesn't register within 10 seconds, push the governor control to the ENGINE STOPPED position to stop the engine. Have corrections made.5. Keep the engine at low idle until the systems are warm.6. Watch all gauges and indicators for correct readings before moving the machine.16°C (60°F) to -12°C (10°F)
1. Follow the steps under "Above 16°C (60°F)."
If the engine does not start after two attempts, use starting fluid. This will prevent excessive battery drain and starting motor overheating.
2. Use starting fluid by pushing the button under the start switch, at 2 second intervals, while cranking the engine. See "Ether Aids" under "Cold Weather Starting Aids."-12°C (10°F) to -26°C (-15°F)
1. Follow the steps under "Above 16°C (60°F)."2. Coolant heaters are required.3. An external battery source may be required if the battery charge is not maintained. See "Boost Starting" under "Cold Weather Starting Aids."4. Starting fluid is required. See "Ether Aids" under "Cold Weather Starting Aids."Below -26°C (-15°F)
1. Follow the steps under "Above 16°C (60°F)."2. Coolant heaters are required.3. An external battery source may be required. See "Boost Starting" under "Cold Weather Starting Aids."4. Starting fluid is required. See "Ether Aids" under "Cold Weather Starting Aids."5. Special lubricants are required. Consult your Caterpillar dealer or refer to Caterpillar Form Number SEBU5338, "Operation, Lubrication and Maintenance Guide for Cold Weather Operation."Starting Aids
Winter Oils
The use of SAE10W viscosity oil in the compartments listed on the chart below will aid in cold weather starting.
Use SAE10W oil only in the temperature ranges indicated.
At lower than above temperatures consult your Caterpillar dealer or refer to the "Operation, Lubrication and Maintenance Guide for Cold Weather Operation," Caterpillar Form Number SEBU5338, for the correct lubricants to use.Ether Aids
Ether is a poison and is flammable.Use it only in well ventilated areas.Use it with care to avoid fires.Avoid breathing the ether vapors, or repeated contact of ether with skin.Do not use ether in environments above 90°C (200°F).
Ether is to be used for cold starting purposes only. Use ether only while cranking the engine. Use it sparingly. Excessive ether can cause piston and ring damage.
Push the button only while cranking the engine.A metered amount of starting fluid (ether) is released each time the button is pushed.After pushing the button, allow 2 seconds before pushing it again.Continue the use of starting fluid every 2 seconds after the engine starts, until it is running smoothly.Batteries
Keep batteries charged to a corrected specific gravity of 1.250 or above. Otherwise, an external electrical source may be required.Boost Starting
Do not allow cable ends to contact each other or the machine.Prevent sparks near the batteries. They could cause battery vapors (hydrogen) to explode.
When