Information injection-pump assembly
ZEXEL
106961-6110
1069616110
ISUZU
1156029120
1156029120

Rating:
Service parts 106961-6110 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-204-1
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.1{225}
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
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)
134424-4020
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
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
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 1-8 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
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.
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
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.
Measure the actual speed.
Timer adjustment_05
Pump speed
r/min
1120
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=5.5deg+-5deg
----------
----------
a=5.5deg+-5deg
0000000901

F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=32.5deg+-3deg
----------
----------
a=10deg+-5deg b=32.5deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=60deg+-5deg b=73deg+-5deg
----------
----------
a=60deg+-5deg b=73deg+-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=10deg
----------
a=(180deg)
----------
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