106961-1077 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069611077 1156014598


106961-1077 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 106961-1077 1069611077
ISUZU 1156014598 1156014598

Cross reference number

ZEXEL 106961-1077 1069611077
ISUZU 1156014598 1156014598


Zexel num
Bosch num
Firm num
Name
106961-1077 
106961-1078 
 
1156014598  ISUZU
INJECTION-PUMP ASSEMBLY
12PC1 * 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   132424-0620
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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   1-4-9-8- 5-2-11-1 0-3-6-7-
Pre-stroke mm   4.4 4.37 4.43
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-4
deg.   15 14.75 15.25
Difference between angles 2
Cal 1-9
deg.   60 59.75 60.25
Difference between angles 3
Cal 1-8
deg.   75 74.75 75.25
Difference between angles 4
Cal 1-5
deg.   120 119.75 120.25
Difference between angles 5
Cyl.1-2
deg.   135 134.75 135.25
Difference between angles 6
Cal 1-11
deg.   180 179.75 180.25
Difference between angles 7
Cal 1-10
deg.   195 194.75 195.25
Difference between angles 8
Cal 1-3
deg.   240 239.75 240.25
Difference between angles 9
Cal 1-6
deg.   255 254.75 255.25
Difference between angles 10
Cal 1-7
deg.   300 299.75 300.25
Difference between angles 11
Cal 1-12
deg.   315 314.75 315.25
Injection quantity adjustment
Adjusting point   A
Rack position   8.5
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   87.2 85.7 88.7
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   8.7
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   102.5 100.5 104.5
Max. variation between cylinders %   0 -3 3
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   8.2+-0.5
Pump speed r/min   1150 1150 1150
Average injection quantity mm3/st.   98.5 94.5 102.5
Max. variation between cylinders %   0 -3 3
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   D
Rack position   5.9+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   8.2 6.8 9.6
Max. variation between cylinders %   0 -13 13
Fixing the rack   *
Injection quantity adjustment_05
Adjusting point   F
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   133 133
Fixing the lever   *
Remarks
When manual lever is on the boost side
 

Test data Ex:

Governor adjustment

Test data 106961-1077
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=1.5mm SXL=10.2+-0.1mm
----------

Timer adjustment

Test data 106961-1077
(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(7)deg t1=1.5--sec. t2=1.5--sec.
----------
N1=950++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=7+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

Test data 106961-1077
F:Full speed
----------

----------
a=7deg+-5deg

0000000901

Test data 106961-1077
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=32deg+-3deg

Stop lever angle

Test data 106961-1077
N:Pump normal S:Stop the pump.
----------

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

0000001101

Test data 106961-1077
N:Normal B:When boosted
----------

----------
a=(5deg) b=(24deg)

0000001501 RACK SENSOR

Test data 106961-1077
V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------

Timing setting

Test data 106961-1077
(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=13deg
----------
a=(170deg)




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