Information injection-pump assembly
ZEXEL
106991-1661
1069911661
ISUZU
1156029572
1156029572
Rating:
Service parts 106991-1661 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-328-0
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.1{225}
15.
NOZZLE SET
Include in #1:
106991-1661
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106991-1661
1069911661
ISUZU
1156029572
1156029572
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-4320
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
5.5
5.47
5.53
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
-
Rack position
11.8
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
131.5
129.9
133.1
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
6.5+-0.5
Pump speed
r/min
430
430
430
Average injection quantity
mm3/st.
13.5
11.5
15.5
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.8)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
131.5
130.5
132.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.9
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
126
122
130
Fixing the lever
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Damper spring setting
----------
T1=AB44
----------
----------
T1=AB44
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(8deg) t1=1.5--sec. t2=1.5--sec.
----------
N1=950++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(8deg) t1=1.5--sec. t2=1.5--sec.
----------
N1=950++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=42.5mm
----------
a=19deg+-5deg b=(30deg)+-3deg
----------
aa=42.5mm
----------
a=19deg+-5deg b=(30deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)-
(2)At pump speed aa and rack position bb, set the stopper bolt. (Confirm non-injection.)
(3)Use the pin above R = cc
----------
aa=0r/min bb=1.5+-0.3mm cc=40mm
----------
a=20deg+-5deg b=43deg+-5deg
----------
aa=0r/min bb=1.5+-0.3mm cc=40mm
----------
a=20deg+-5deg b=43deg+-5deg
0000001501 RACK SENSOR
Rack sensor adjustment
1. Flange type rack sensor (rack sensor adjustment -5*20)
(1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures.
(2)Mount the rack sensor main body to the pump main body.
(3)Fix the pump lever at full.
(4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist.
(5)Move the pump lever two or three times.
(6)Set again to full.
(7)Confirm that the amplifier output voltage is Vist.
(8)Fix the caution plate to the upper part of the rack sensor.
(For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.)
(9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=790r/min Ra=R1(11.8)+0.2mm Vist=1.55+-0.14V
----------
----------
V1=5+-0.01V N1=790r/min Ra=R1(11.8)+0.2mm Vist=1.55+-0.14V
----------
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
(4)-
----------
aa=4deg
----------
a=(180deg)
----------
aa=4deg
----------
a=(180deg)
Information:
2. Locate wire 405-GY on the main cab harness near the connector exiting the cab wall on the right hand side, as shown by arrow.Cut this wire close to the connector. Splice it and the wire just assembled using an 8S4626 Splice. Be sure to splice to the portion of the wire that goes into the cab harness.3. Connect the 7N9738 Housing to the two pin connector on the 8X9862 Harness Assembly (housing containing 405-GY). Clip with a 3T3048 Clip Assembly.Installation of Ether (Chassis) Wiring Harness
The ether chassis harness for MPPS is different than the one called out in the AEIS Special Instruction.* Substitute 8X8468 Harness Assembly for 8X7653 Harness Assembly on the 785 Trucks.* Substitute 8X8467 Harness Assembly for 8X7652 Harness Assembly on the 789 Trucks.Follow the installation procedure outlined in the AEIS Special Instruction for the Ether Chassis Harness Assembly. Be sure to use the 8X8466 Wire Assembly for the 785 Trucks or the 8X8429 Wire Assembly for the 789 Trucks. This is the new harness code plug required with MPPS.Installation of 8X8469 Ether (Engine) Wiring Harness
The 8X7106 Engine Harness on the AEIS is replaced with 8X8469 Harness Assembly.Follow the installation procedure outlined in the AEIS Special Instruction for the 8X7106 Harness Assembly. In addition, the following steps need to be performed. 1. Route the end of the harness with the 8T8732 Receptacle to the 3E3530 Electronic Control Group (oil pressure sensor) installed at the right rear of the engine as shown.2. Connect the three pin receptacle to the connector on the 3E3530 Electronic Control Group (2) and clip into the 9X3495 Clip Assembly (7) installed earlier. Use 3S2093 Straps (8) to loosely secure the harness to the top rear of the engine as shown.3. Remove the 8W3048 Harness Assembly that is connected to the remaining 6T7663 Oil Pressure Switch (9) and was connected to the 6T7663 Oil Pressure Switch (9) that was removed.4. Connect an 8X8337 Harness Assembly (10) to the one remaining oil pressure switch and reconnect to the engine harness. Clip with the existing clip. DO NOT tighten the straps or clips until all new wiring harnesses have been installed so any repositioning or adjustments can be made as necessary.Checking the Automatic Ether Injection System
* The system check-out will be same as for the AEIS with the following change: "A5" harness code on the 785 (indicates 3512 application) or "A6" harness code on the 789 (indicates 3516 application) for two seconds.Retrofit to an Existing AEIS System
Necessary Parts
Installation of 3E3778 Ether Control Group
The 3E3778 Control Group is required for the MPPS System.Check the electronic control box installed with the AEIS to see if it is a 3E3778 or a 9X5303 Control Group. If a 9X5303 control Group is installed, replace it with 3E3778 Control Group and 3E3779 Film.Follow the "Installation of 9X5303 Ether Control Group" instructions outlined in the AEIS installation Special Instruction, SEHS9293. Be sure to install the 8X8398 Wire Assembly between the control and mounting plate. If an MPPS identification film is
The ether chassis harness for MPPS is different than the one called out in the AEIS Special Instruction.* Substitute 8X8468 Harness Assembly for 8X7653 Harness Assembly on the 785 Trucks.* Substitute 8X8467 Harness Assembly for 8X7652 Harness Assembly on the 789 Trucks.Follow the installation procedure outlined in the AEIS Special Instruction for the Ether Chassis Harness Assembly. Be sure to use the 8X8466 Wire Assembly for the 785 Trucks or the 8X8429 Wire Assembly for the 789 Trucks. This is the new harness code plug required with MPPS.Installation of 8X8469 Ether (Engine) Wiring Harness
The 8X7106 Engine Harness on the AEIS is replaced with 8X8469 Harness Assembly.Follow the installation procedure outlined in the AEIS Special Instruction for the 8X7106 Harness Assembly. In addition, the following steps need to be performed. 1. Route the end of the harness with the 8T8732 Receptacle to the 3E3530 Electronic Control Group (oil pressure sensor) installed at the right rear of the engine as shown.2. Connect the three pin receptacle to the connector on the 3E3530 Electronic Control Group (2) and clip into the 9X3495 Clip Assembly (7) installed earlier. Use 3S2093 Straps (8) to loosely secure the harness to the top rear of the engine as shown.3. Remove the 8W3048 Harness Assembly that is connected to the remaining 6T7663 Oil Pressure Switch (9) and was connected to the 6T7663 Oil Pressure Switch (9) that was removed.4. Connect an 8X8337 Harness Assembly (10) to the one remaining oil pressure switch and reconnect to the engine harness. Clip with the existing clip. DO NOT tighten the straps or clips until all new wiring harnesses have been installed so any repositioning or adjustments can be made as necessary.Checking the Automatic Ether Injection System
* The system check-out will be same as for the AEIS with the following change: "A5" harness code on the 785 (indicates 3512 application) or "A6" harness code on the 789 (indicates 3516 application) for two seconds.Retrofit to an Existing AEIS System
Necessary Parts
Installation of 3E3778 Ether Control Group
The 3E3778 Control Group is required for the MPPS System.Check the electronic control box installed with the AEIS to see if it is a 3E3778 or a 9X5303 Control Group. If a 9X5303 control Group is installed, replace it with 3E3778 Control Group and 3E3779 Film.Follow the "Installation of 9X5303 Ether Control Group" instructions outlined in the AEIS installation Special Instruction, SEHS9293. Be sure to install the 8X8398 Wire Assembly between the control and mounting plate. If an MPPS identification film is