Information injection-pump assembly
ZEXEL
106991-1022
1069911022
ISUZU
1156025002
1156025002
Rating:
Service parts 106991-1022 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:
106991-1022
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106991-1022
1069911022
ISUZU
1156025002
1156025002
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)
134424-4020
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
1-4-9-8-
5-2-11-1
0-3-6-7-
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 1-4 deg. 15 14.75 15.25
Cal 1-4 deg. 15 14.75 15.25
Difference between angles 2
Cal 1-9 deg. 60 59.75 60.25
Cal 1-9 deg. 60 59.75 60.25
Difference between angles 3
Cal 1-8 deg. 75 74.75 75.25
Cal 1-8 deg. 75 74.75 75.25
Difference between angles 4
Cal 1-5 deg. 120 119.75 120.25
Cal 1-5 deg. 120 119.75 120.25
Difference between angles 5
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 6
Cal 1-11 deg. 180 179.75 180.25
Cal 1-11 deg. 180 179.75 180.25
Difference between angles 7
Cal 1-10 deg. 195 194.75 195.25
Cal 1-10 deg. 195 194.75 195.25
Difference between angles 8
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 9
Cal 1-6 deg. 255 254.75 255.25
Cal 1-6 deg. 255 254.75 255.25
Difference between angles 10
Cal 1-7 deg. 300 299.75 300.25
Cal 1-7 deg. 300 299.75 300.25
Difference between angles 11
Cal 1-12 deg. 315 314.75 315.25
Cal 1-12 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
8.3
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
107.8
106.3
109.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
109.4
107.4
111.4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.9
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
116.9
114.9
118.9
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
800+-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=2.1mm
----------
----------
RT=0.8 TH=2.1mm
----------
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=33deg+-3deg
----------
----------
a=10deg+-5deg b=33deg+-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)-
----------
----------
a=(180deg)
----------
----------
a=(180deg)
Information:
Changing Ether Cylinders
Ether is poisonous and flammable.Do not store replacement ether cylinders in living areas or in the operator's compartment.Do not smoke while changing ether cylinders.Use ether only in well ventilated areas.Use it with care to avoid fires.Keep the cylinders out of the reach of children.Avoid breathing ether vapors or repeated contact of ether with the skin.Do not store cylinders in direct sunlight.Do not puncture or burn the cylinders.Discard the cylinders in a safe place.
The ether cylinder is located at the right front of the machine, inside the guard. 1. Remove the two bolts to open the guard. 2. Loosen the clamp (1). Unscrew the cylinder (2). 3. Remove the used gasket and replace it with the new one provided with each new cylinder. 4. Install a new cylinder and tighten it hand tight. Tighten the clamp.5. Close the guard and install the retaining bolts.
Remove the ether cylinder before shipping the machine.
Draft Frame Arms
(631, 633, 637, 639)
Adjust
The draft frame arms and the scraper bowl can be in contact, but there must be no wear between them. Install wear shoe and shims, as needed, on the inside of draft frame arm. The clearance between the draft frame arm and the scraper bowl must not exceed .00 + 3.0 - .00 mm (.00 + .12 - .00 in).Refer to the Service Manual for your machine or contact your Caterpillar dealer for the correct adjustment procedures.
Ether is poisonous and flammable.Do not store replacement ether cylinders in living areas or in the operator's compartment.Do not smoke while changing ether cylinders.Use ether only in well ventilated areas.Use it with care to avoid fires.Keep the cylinders out of the reach of children.Avoid breathing ether vapors or repeated contact of ether with the skin.Do not store cylinders in direct sunlight.Do not puncture or burn the cylinders.Discard the cylinders in a safe place.
The ether cylinder is located at the right front of the machine, inside the guard. 1. Remove the two bolts to open the guard. 2. Loosen the clamp (1). Unscrew the cylinder (2). 3. Remove the used gasket and replace it with the new one provided with each new cylinder. 4. Install a new cylinder and tighten it hand tight. Tighten the clamp.5. Close the guard and install the retaining bolts.
Remove the ether cylinder before shipping the machine.
Draft Frame Arms
(631, 633, 637, 639)
Adjust
The draft frame arms and the scraper bowl can be in contact, but there must be no wear between them. Install wear shoe and shims, as needed, on the inside of draft frame arm. The clearance between the draft frame arm and the scraper bowl must not exceed .00 + 3.0 - .00 mm (.00 + .12 - .00 in).Refer to the Service Manual for your machine or contact your Caterpillar dealer for the correct adjustment procedures.