Information injection-pump assembly
ZEXEL
106961-6090
1069616090
ISUZU
1156028380
1156028380
Rating:
Cross reference number
ZEXEL
106961-6090
1069616090
ISUZU
1156028380
1156028380
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)
134424-4320
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)
134424-4320
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
4.4
4.37
4.43
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.
96.1
94.6
97.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.6
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
96.8
94.8
98.8
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.
101.1
99.1
103.1
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
5.2+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8.8
7.5
10.1
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Timer adjustment
Pump speed
r/min
600--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
550
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
830+-30
Advance angle
deg.
2
1.5
2.5
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
2
1.5
2.5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_05
Pump speed
r/min
1100
Advance angle
deg.
5.5
5
6
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Damper spring setting
----------
----------
----------
----------
Speed control lever angle
F:Full speed
----------
----------
a=7deg+-5deg
----------
----------
a=7deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=31deg+-3deg
----------
----------
a=10deg+-5deg b=31deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=25mm
----------
a=64deg+-5deg b=51deg+-5deg
----------
aa=25mm
----------
a=64deg+-5deg b=51deg+-5deg
0000001301
I:Idle
F:Full load
(1)Stopper bolt setting
----------
----------
a=31deg+-3deg b=14.5deg+-5deg
----------
----------
a=31deg+-3deg b=14.5deg+-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)-
----------
aa=8deg
----------
a=(180deg)
----------
aa=8deg
----------
a=(180deg)
Information:
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Illustration 1 g06531932
Typical example
(1) 310-4948 Clip
(2) 310-4947 Clip
(3) 536-7106 Grommet
Illustration 2 g06533545
Typical view of DEF lines group in 794 AC/ 796 AC/ 798 AC machines
Table 1
Required Parts
Item Qty New Part Number Part Name Former Part Number(1)
1 12(2) 310-4948 Clip 3G-8054
2 12(2) 310-4947 Clip 3G-8057
3 12(2) 536-7106 Grommet 3G-8047
(1) The former part number listed is for reference only and may differ.
(2) 785G machines require only 8 quantity.New 310-4948 Clip (1) replaces the former 3G-8054 Clip in the DEF lines group/heater lines group.New 310-4947 Clip (2) replaces the former 3G-8057 Clip in the DEF lines group/heater lines group.New 536-7106 Grommet (3) replaces the former 3G-8047 Grommet in the DEF lines group/heater lines group.