106961-1506 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069611506 1156017218

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106961-1506 1069611506

ISUZU 1156017218 1156017218

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Buy INJECTION-PUMP ASSEMBLY 106961-1506 zexel genuine, new aftermarket engine parts with delivery

Service parts 106961-1506 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106096-9301

3. GOVERNOR 105488-0452

4. SUPPLY PUMP 105237-1940

5. AUTOM. ADVANCE MECHANIS 105687-0152

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7192

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-4831

14. NOZZLE

105015-6651

15. NOZZLE SET

Include in #1:

106961-1506 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106961-1506 1069611506

ISUZU 1156017218 1156017218

Zexel num

Bosch num

Firm num

Name

106961-1506
106961-1507

1156017218 ISUZU

INJECTION-PUMP ASSEMBLY
10PC1 * K

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 (drive side) 134424-3520

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

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 B

Rack position 8.1

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 85.6 84.1 87.1

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.9+-0.5

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 95.9 91.9 99.9

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 5.4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8 6.6 9.4

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Injection quantity adjustment_04

Adjusting point F

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 137 137

Fixing the lever *

Remarks
When manual lever is on the boost side

Injection quantity adjustment_05

Adjusting point G

Rack position 8.1

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 94.8 90.8 98.8

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Timer adjustment

Pump speed r/min 750+50

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000+50

Advance angle deg. 1 0.5 1

Load 3/4

Timer adjustment_03

Pump speed r/min (1075)

Advance angle deg. 1 0.5 1

Load 4/4

Timer adjustment_04

Pump speed r/min 1150

Advance angle deg. 3 2.7 3.3

Load 4/4

Timer adjustment_05

Pump speed r/min 1250

Advance angle deg. 6 5.4 6.6

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Supplied with damper spring not set. (2)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. (3)At excess fuel lever operation: not exceeding EXL (4)Excess fuel setting for starting: SXL
----------
EXL=2mm SXL=9.2+-0.1mm
----------

Speed control lever angle

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

----------
a=9deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=35mm
----------
a=10deg+-5deg b=33deg+-3deg

Stop lever angle

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

----------
a=60deg+-5deg b=73deg+-5deg

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=12deg
----------
a=(170deg)

Information:

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Remove any coolant lines that may interfere with the installation. Remove any air inlet lines that may interfere with the installation.
Illustration 1 g01006397
Typical example (1) Bolt (2) Washer (3) Air inlet cover
Remove bolt (1) and the washer (2) from the air inlet cover (3). Discard the bolt (1) and the washer (2) .
Disconnect the electrical connector of the injection actuation pressure control valve (7). Remove the injection actuation pressure control valve (7) from the pump. Retain the injection actuation pressure control valve (7) for the reinstallation.Note: Modifications to the tools may need to be made in order to reduce interference with engine components.
Illustration 2 g01007381
Modified 2P-5494 crowfoot wrench
Remove the hose assembly (5), the connector (8), and the elbow (6). Discard these parts.
Illustration 3 g01006381
(4) HEUI pump (5) Flexible oil line (6) Elbow (7) Injection actuation pressure control valve (8) ConnectorInstallation of the 240-0716 Tube Kit
Illustration 4 g01006407
(4) HEUI pump (7) Injection actuation pressure control valve (9) Connector (10) Clip (11) Washer (12) Bolt (13) Spacer (14) Tube assembly (15) O-ring (16) O-ring (17) Elbow
Illustration 5 g01006437
(7) Injection actuation pressure control valve (9) Connector (15) O-ring (16) O-ring (17) Elbow
Apply a light coat of oil to the O-rings (15) and (16) during installation. Install the O-ring (15) on the connector (9). Install the O-ring (16) on the connector (9). Thread the connector (9) into the port on the cylinder head by hand. Tighten to 48 + 5 N m (35 + 4 lb ft).
Apply a light coat of oil to the O-rings (15) and (16) during installation. Install the O-ring (15) on the elbow (17). Install the O-ring (16) on the elbow (17).
Back off the jam nut on the elbow (17) to the top of the threads on the elbow assembly (17). Push the washer tightly against the jam nut. Check that the washer is as tight as possible. Thread the elbow assembly (17) into the port of the HEUI pump (4). Hand tighten the elbow (17) into the port of the HEUI pump until the washer is tight against the HEUI pump (4). Unscrew the elbow assembly (17) no more than one complete turn to 40 degrees.
Align the tube assembly (14) with the connector (9) and the elbow (17). Loosely thread each end of the tube assembly (14) onto the connector (9) and the elbow (17). Position the elbow (17) in order to not create stress in the tube assembly (14) .
Attach the clip (10) to the tube assembly (14). The flat side of the clip (10) must be toward the air inlet cover. Place the washer (11) onto the bolt