Information injection-pump assembly
ZEXEL
106991-1663
1069911663
ISUZU
1156029574
1156029574
Rating:
Service parts 106991-1663 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:
106991-1663
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106991-1663
1069911663
ISUZU
1156029574
1156029574
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=AD47
----------
----------
T1=AD47
----------
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=1-0.2(mm) N2=800r/min C2=(8)deg 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=1-0.2(mm) N2=800r/min C2=(8)deg 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=22.5deg+-5deg b=(28deg)+-3deg
----------
aa=42.5mm
----------
a=22.5deg+-5deg b=(28deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
(2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=20deg+-5deg b=43deg+-5deg
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
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:
Power Plug To Chassis Harness
Connect 777-PU wire to 777-PU wire on chassis harness.Starter Connections
The connector with the plug in Loc. 3, connects to the bottom starter. The connector without the plug in Loc. 3, goes to the top starter.Air Conditioner (Attachment).
8C9677 Harness Assembly1. Install 8C9677 Harness Assembly to the air conditioner (513-OR and 200-BK).2. Remove plug housing from the EUI engine harness and connect the 2 pin sure seal breakout to 8C9677 Air Conditioner Harness Assembly.Steering Flow Switch.
Connect the 2 pin sure seal breakout to the steering flow switch.Ether System
* Trucks equipped with auto ether system with Multi-Point Oil Pressure Sensing perform the following steps:
8X5415 Wire AssemblyRemove the code plug installed in the chassis auto ether harness on top of the left fore-aft beam near the cab and replace it with 8X5415 Wire Assembly. This disables the multi-point oil pressure function.Remove the engine oil pressure sensor control and its hardware on the right rear of the engine. It will be replaced by the oil pressure sensor for the EUI system.* Trucks with auto ether system where the ether coolant sensor is located in the water regulator housing on the left side of the engine perform the following steps: If the truck has the ether coolant sensor in location (A), the new EUI cover (7E5326) must be reworkedThe bottom right port (B) must be changed to No. 6 Port. Drill and tape for (9/16-18-2B threads).Move the ether coolant sensor to location (B), new No. Port 6. Relocate the connector clip to the lower right bolt of the cover if necessary to retain connection.Tachograph Group
8X8529 Tachometer Group (1) 4N3695 Cable Assembly. (2) Two 338248 Clips. (3) 5M3062 Bolt. (4) 8T4896 Washer.1. Install the 8X8529 Tachometer Drive Group as shown in the illustration above.Tighten the tach cable to 11.3 1.8 N m (100.0 15.9 lb in) at the engine end and 5.7 0.9 N m (50.4 8.0 lb in) at the cab end.2. This completes the EUI retro-fit installation.3. Clean and paint all welded areas.4. Secure all harnesses and wires with tie wraps.5. Check all areas that were modified or changed.6. Connect the batteries.Description Of New Lamps And Switches On New Dash Plate
* CHECK ENGINE LAMP (1)This lamp is used to indicate when a problem exists in the engines electronic control systemThe indicator will come on when the start switch is in the ON position and the engine is not operating. The lamp will stay on approximately 5 seconds, then go out.This lamp is also used to read diagnostic flash codes in conjunction with the diagnostic enable switch.* AIR FILTER RESTRICTION LAMP (2)This lamp indicates that the engine air intake filters are plugged.If the indicator comes on, service the filters that day.* ENGINE OVERSPEED LAMP (3)This lamp indicates the engine rpm is too high. The engine overspeed alarm will sound also when the engine is exceeding maximum allowable limit for safe operation. The lamp and alarm will remain ON as long as the engine is overspeeding.* THROTTLE
Connect 777-PU wire to 777-PU wire on chassis harness.Starter Connections
The connector with the plug in Loc. 3, connects to the bottom starter. The connector without the plug in Loc. 3, goes to the top starter.Air Conditioner (Attachment).
8C9677 Harness Assembly1. Install 8C9677 Harness Assembly to the air conditioner (513-OR and 200-BK).2. Remove plug housing from the EUI engine harness and connect the 2 pin sure seal breakout to 8C9677 Air Conditioner Harness Assembly.Steering Flow Switch.
Connect the 2 pin sure seal breakout to the steering flow switch.Ether System
* Trucks equipped with auto ether system with Multi-Point Oil Pressure Sensing perform the following steps:
8X5415 Wire AssemblyRemove the code plug installed in the chassis auto ether harness on top of the left fore-aft beam near the cab and replace it with 8X5415 Wire Assembly. This disables the multi-point oil pressure function.Remove the engine oil pressure sensor control and its hardware on the right rear of the engine. It will be replaced by the oil pressure sensor for the EUI system.* Trucks with auto ether system where the ether coolant sensor is located in the water regulator housing on the left side of the engine perform the following steps: If the truck has the ether coolant sensor in location (A), the new EUI cover (7E5326) must be reworkedThe bottom right port (B) must be changed to No. 6 Port. Drill and tape for (9/16-18-2B threads).Move the ether coolant sensor to location (B), new No. Port 6. Relocate the connector clip to the lower right bolt of the cover if necessary to retain connection.Tachograph Group
8X8529 Tachometer Group (1) 4N3695 Cable Assembly. (2) Two 338248 Clips. (3) 5M3062 Bolt. (4) 8T4896 Washer.1. Install the 8X8529 Tachometer Drive Group as shown in the illustration above.Tighten the tach cable to 11.3 1.8 N m (100.0 15.9 lb in) at the engine end and 5.7 0.9 N m (50.4 8.0 lb in) at the cab end.2. This completes the EUI retro-fit installation.3. Clean and paint all welded areas.4. Secure all harnesses and wires with tie wraps.5. Check all areas that were modified or changed.6. Connect the batteries.Description Of New Lamps And Switches On New Dash Plate
* CHECK ENGINE LAMP (1)This lamp is used to indicate when a problem exists in the engines electronic control systemThe indicator will come on when the start switch is in the ON position and the engine is not operating. The lamp will stay on approximately 5 seconds, then go out.This lamp is also used to read diagnostic flash codes in conjunction with the diagnostic enable switch.* AIR FILTER RESTRICTION LAMP (2)This lamp indicates that the engine air intake filters are plugged.If the indicator comes on, service the filters that day.* ENGINE OVERSPEED LAMP (3)This lamp indicates the engine rpm is too high. The engine overspeed alarm will sound also when the engine is exceeding maximum allowable limit for safe operation. The lamp and alarm will remain ON as long as the engine is overspeeding.* THROTTLE