106961-6110 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069616110 1156029120


 

Information injection-pump assembly

ZEXEL 106961-6110 1069616110
ISUZU 1156029120 1156029120
106961-6110 INJECTION-PUMP ASSEMBLY
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Service parts 106961-6110 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106096-9560
3. GOVERNOR 105487-4950
4. SUPPLY PUMP 105237-4420
5. AUTOM. ADVANCE MECHANIS 105687-0500
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-7851
11. Nozzle and Holder 1-15300-204-1
12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.1{225}
13. NOZZLE-HOLDER 105031-4831
14. NOZZLE 105015-8200
15. NOZZLE SET

Include in #1:

106961-6110 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106961-6110 1069616110
ISUZU 1156029120 1156029120


Zexel num
Bosch num
Firm num
Name
106961-6110 
106961-6111 
 
1156029120  ISUZU
INJECTION-PUMP ASSEMBLY
10PD1 * 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)   134424-4020
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   4.4 4.37 4.43
Rack position
Point A
  R=A
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   7.9
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   100 98.5 101.5
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   7.9
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   112 108 116
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   7.5
Pump speed r/min   1150 1150 1150
Average injection quantity mm3/st.   109 107 111
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   -
Rack position   4.9+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   13.5 12.2 14.8
Max. variation between cylinders %   0 -13 13
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Timer adjustment
Pump speed r/min   620--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   570
Advance angle deg.   0.3
Timer adjustment_03
Pump speed r/min   850+-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.
 
Timer adjustment_05
Pump speed r/min   1120
Advance angle deg.   5.5 5 6
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106961-6110
N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Damper spring setting
----------

----------

Speed control lever angle

Test data 106961-6110
F:Full speed
----------

----------
a=5.5deg+-5deg

0000000901

Test data 106961-6110
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=32.5deg+-3deg

Stop lever angle

Test data 106961-6110
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 106961-6110
(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=10deg
----------
a=(180deg)




Information:


Table 1
Revision Summary of Changes
01 Updated the effectivity. A new Diesel Exhaust Fluid (DEF) filter is now available on machines listed above. The DEF filter has an improved filter efficiency.
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.
The following changes are now available for the products within the listed serial numbers.Refer to Table 2 for a list of a new and former part numbers.
Table 2
Required Parts
DEF Filter DEF Manifold Group
Application New Part Number Part Name Former Part Number (1) New Part Number Part Name Former Part Number (1)
785G 584-8139 DEF Filter 453-1607 585-3956 DEF Manifold Gp 480-4090
789G, 793F, 794AC, 797F, and 994K 584-8140 DEF Filter 453-1608 585-3957 DEF Manifold Gp 480-4091
(1) The former part number listed is for reference only and may differ.Note: The new DEF manifold group part numbers listed in Table 2 will be assembled with the new filters.
Illustration 1 g06570567
DEF manifold
(1) ClampAn additional change, beyond the new DEF filter, was made to the 585-3957 DEF Manifold Gp. The clamp in the location highlighted in Illustration 2 was removed to eliminate a potential wear point.
Illustration 2 g06570636
Typical view of the DEF manifold group
(2) DEF manifold
(3) DEF filterThis change is effective for the Pump Electronic Tank Unit (PETU) serial numbers listed in Table 3.
Table 3
Pump Electronic Tank Unit (PETU) Serial Numbers
S/N:PET001414J
S/N:PET001444J-UP

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