Information injection-pump assembly
ZEXEL
106991-1005
1069911005
ISUZU
1156021875
1156021875
Rating:
Service parts 106991-1005 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:
106991-1005
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106991-1005
1069911005
ISUZU
1156021875
1156021875
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
4.2
4.17
4.23
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
8.5
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
110
108.5
111.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.8
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
111.6
109.6
113.6
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.9
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
117.4
115.4
119.4
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
4.9+-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
800+-30
Advance angle
deg.
2
1.5
2.5
Timer adjustment_04
Pump speed
r/min
870
Advance angle
deg.
2
1.7
2.3
Timer adjustment_05
Pump speed
r/min
(1050)
Advance angle
deg.
3.5
3
4
Timer adjustment_06
Pump speed
r/min
1150
Advance angle
deg.
5.5
5
6
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Damper spring setting
----------
RT=0.8 TH=2mm
----------
----------
RT=0.8 TH=2mm
----------
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=34deg+-3deg
----------
----------
a=10deg+-5deg b=34deg+-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=8deg
----------
a=(180deg)
----------
aa=8deg
----------
a=(180deg)
Information:
Above 32°F (0°C)
Make sure no one is working on or close to the machine before starting the engine. Fasten seat belt.
1. Make certain TRANSMISSION NEUTRAL LOCK and PARKING BRAKE LOCKING lever is engaged. Move all implement controls to HOLD. 2. Insert the key in the disconnect switch and turn the switch ON.
Never turn the disconnect switch OFF with the engine running.
3. Move the governor control lever to the low idle position just past the detent. 4. Push in and turn the START switch to START. Release the switch when the engine starts.Below 32°F (0°C)
1. Follow steps 1-thru-4 for above 32°F (0°C). If engine does not start, push in the Starting Aid Button. A metered amount of starting fluid, sufficient to help start the engine, is released each time the Starting Aid Button is pushed in. 2. While cranking the engine use additional Starting Aid Fluid every 2 seconds, by pushing the button in and releasing it. 3. Release the START switch when the engine starts.4. If necessary continue the use of Starting Aid Fluid every 2 seconds after the engine starts, until it runs smoothly.
After every 30 seconds of cranking, allow 2 minutes for the starting motor to cool.
5. If extra battery capacity is needed, refer to the Operator's Guide SEBU5516 - 955L, 977L & 983B Track Type Loaders.6. Refer to the Operator's Guide for after starting checks, warm up procedure and engine shutdown. For starting below 0°F (-18°C) the use of optional cold weather starting aids is recommended. A coolant heater, jacket water heater or extra battery capacity may be required.
The Starting Aid Ether Bottle must be removed before transporting the machine. See the Lubrication and Maintenance Guide SEBU5515 for removal and replacing the bottle.
Make sure no one is working on or close to the machine before starting the engine. Fasten seat belt.
1. Make certain TRANSMISSION NEUTRAL LOCK and PARKING BRAKE LOCKING lever is engaged. Move all implement controls to HOLD. 2. Insert the key in the disconnect switch and turn the switch ON.
Never turn the disconnect switch OFF with the engine running.
3. Move the governor control lever to the low idle position just past the detent. 4. Push in and turn the START switch to START. Release the switch when the engine starts.Below 32°F (0°C)
1. Follow steps 1-thru-4 for above 32°F (0°C). If engine does not start, push in the Starting Aid Button. A metered amount of starting fluid, sufficient to help start the engine, is released each time the Starting Aid Button is pushed in. 2. While cranking the engine use additional Starting Aid Fluid every 2 seconds, by pushing the button in and releasing it. 3. Release the START switch when the engine starts.4. If necessary continue the use of Starting Aid Fluid every 2 seconds after the engine starts, until it runs smoothly.
After every 30 seconds of cranking, allow 2 minutes for the starting motor to cool.
5. If extra battery capacity is needed, refer to the Operator's Guide SEBU5516 - 955L, 977L & 983B Track Type Loaders.6. Refer to the Operator's Guide for after starting checks, warm up procedure and engine shutdown. For starting below 0°F (-18°C) the use of optional cold weather starting aids is recommended. A coolant heater, jacket water heater or extra battery capacity may be required.
The Starting Aid Ether Bottle must be removed before transporting the machine. See the Lubrication and Maintenance Guide SEBU5515 for removal and replacing the bottle.