106961-1040 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069611040 1156014561

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106961-1040 1069611040

ISUZU 1156014561 1156014561

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Buy INJECTION-PUMP ASSEMBLY 106961-1040 zexel genuine, new aftermarket engine parts with delivery

Service parts 106961-1040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106096-9110

3. GOVERNOR 105488-8720

4. SUPPLY PUMP 105237-1390

5. AUTOM. ADVANCE MECHANIS 105693-0060

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7003

11. Nozzle and Holder 1-15300-138-2

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.1{225}

13. NOZZLE-HOLDER 105031-4831

14. NOZZLE

105015-6250

15. NOZZLE SET

Include in #1:

106961-1040 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106961-1040 1069611040

ISUZU 1156014561 1156014561

Zexel num

Bosch num

Firm num

Name

106961-1040
106961-1048

1156014561 ISUZU

INJECTION-PUMP ASSEMBLY
10PC1 *

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-7-6- 5-4-3-10 -9-2

Pre-stroke mm 4 3.97 4.03

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 27 26.75 27.25

Difference between angles 2
Cal 1-7 deg. 72 71.75 72.25

Difference between angles 3
Cal 1-6 deg. 99 98.75 99.25

Difference between angles 4
Cal 1-5 deg. 144 143.75 144.25

Difference between angles 5
Cal 1-4 deg. 171 170.75 171.25

Difference between angles 6
Cal 1-3 deg. 216 215.75 216.25

Difference between angles 7
Cal 1-10 deg. 243 242.75 243.25

Difference between angles 8
Cal 1-9 deg. 288 287.75 288.25

Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 8.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 89.8 88.3 91.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 105.7 103.7 107.7

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.5+-0.5

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 108 104 112

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 6.8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 14.5 13.1 15.9

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_05

Adjusting point F

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 135 135

Fixing the lever *

Remarks
When manual lever is on the boost side

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Supply solenoid operating voltage DC24V and move the solenoid body so that the excess lever reaches the excess position at the solenoid's maximum stroke. (2)Supplied with damper spring not set. (3)At excess fuel lever operation: not exceeding EXL (4)Excess fuel setting for starting: SXL
----------
EXL=1.5mm SXL=10.2+-0.1mm
----------

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=(7.5)deg t1=1.5--sec. t2=1.5--sec.
----------
N1=1100++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=7.5+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
----------

----------
a=10deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=32deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=36deg+-5deg b=73deg+-3deg

0000001101

N:Normal B:When boosted
----------

----------
a=(5deg) b=(24deg)

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=13deg
----------
a=(170deg)

Information:

PROBLEM
On certain C175-16 and C175-20 Generator Sets the 276-1242 4 pin connector that connects the engine harness to the individual cylinder injector harnesses may not be fully latched do to a damaged connector locking tab.
AFFECTED PRODUCT
Model Identification Number
C175-16 WYB00649-00652, 656, 664-665, 1231-1232, 1237, 1241, 1243, 1249, 1253-1254, 1413, 1417, 1424, 1426, 1431, 1434, 1436, 1438, 1476, 1478-1484, 1508, 1564, 1566, 1569-1570, 1573-1574, 1578, 1610, 1612, 1614, 1622, 1625, 1627, 1630, 1825-1826, 1840-1841, 1846-1853, 1857-1860, 1862-1863, 1869-1871, 1873, 1876-1878, 1885, 1888-1891, 1895, 1899, 1904-1909, 1911, 1914-1920, 1925-1927, 1929, 1931-1932, 1936-1940, 1954, 1956, 1958, 2075, 2084, 2087-2088, 2091-2092, 2095-2096, 2098, 2100-2105, 2108-2109, 2112-2113, 2115-2116, 2118, 2127-2129, 2136-2142, 2179, 2182-2185, 2189, 2192-2193, 2195-2196, 2198, 2200, 2203, 2206-2209, 2214, 2227, 2229, 2232-2233, 2244, 2246, 2248-2257, 2332, 2337, 2342, 2352-2353, 2355-2356, 2359, 2362-2364, 2370-2371, 2416, 2437, 2470, 2475, 2479, 2481, 2493, 2500
C175-20 BXR01781, 1798-1807, 1809, 1826, 1828, 1944-1950, 1953-1956, 1959-1960, 1962, 2013-2014, 2026-2027, 2029, 2036, 2042-2046, 2048-2050, 2055-2058
PARTS NEEDED
Qty
Part Number Description
1 4C6389 TUBING-HEAT SHRI
1 1134630 RECEPTACLE AS
1 2300940 SEAL-PIP
1 2761242 KIT-PLUG CONN
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
1. Inspect 276-1242 4 pin engine harness connector and check the connector locking tab for proper engagement with injector harness receptacle. Image 1 is a damaged locking tab. Image 2 is a good locking tab. If locking tab is found to be damage proceed with replacement.
2. Disconnect the 276-1242 4 pin engine harness connector from the 113-4630 injector harness receptacle at the cylinder head.
3. Remove and replace 276-1242 4 pin connector with new. Insure to reinstall 4C-6389 heat shrink on the connector.
4. Inspect the inside of 113-4630 injector harness receptacle mounted on cylinder head for debris, damage, or paint. If debris, damage, or paint is present, remove and replace 113-4630 injector harness receptacle with new.
Note: Always use a new valve cover gasket if removal of valve cover is required.
5. Reconnect new 276-1242 4 pin engine harness connector to the new 113-4630 injector harnesses receptacle. Insure the connector is fully seated, audible click is heard, lock tab in the proper position, and connector cannot be pulled out.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-600 hrs,
0-45 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.