106961-1877 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069611877 1156021916


106961-1877 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 106961-1877 1069611877
ISUZU 1156021916 1156021916

Cross reference number

ZEXEL 106961-1877 1069611877
ISUZU 1156021916 1156021916


Zexel num
Bosch num
Firm num
Name
106961-1877 
106961-1876 
 
1156021916  ISUZU
INJECTION-PUMP ASSEMBLY
10PC1 *

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)   134424-3520
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 3.97 4.03
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   8.1
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   85.6 84.1 87.1
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   7.9+-0.5
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   95.9 91.9 99.9
Max. variation between cylinders %   0 -3 3
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   5.4+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   8 6.6 9.4
Max. variation between cylinders %   0 -13 13
Fixing the rack   *
Injection quantity adjustment_04
Adjusting point   E
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   137 137
Fixing the lever   *
Remarks
When manual lever is on the boost side
 
Injection quantity adjustment_05
Adjusting point   F
Rack position   8.1
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   94.8 90.8 98.8
Max. variation between cylinders %   0 -3 3
Fixing the lever   *
Timer adjustment
Pump speed r/min   750+50
Advance angle deg.   0 0 0
Load   1/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1000+50
Advance angle deg.   1 0.5 1
Load   3/4
Timer adjustment_03
Pump speed r/min   (1075)
Advance angle deg.   1 0.5 1
Load   4/4
Timer adjustment_04
Pump speed r/min   1150
Advance angle deg.   3 2.7 3.3
Load   4/4
Timer adjustment_05
Pump speed r/min   1250
Advance angle deg.   6 5.5 6.5
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106961-1877
N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Supplied with damper spring not set. (4)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. (5)At excess fuel lever operation: not exceeding EXL (6)Excess fuel setting for starting: SXL
----------
RT=0.8 TH=2.3mm EXL=2mm SXL=9.2+-0.1mm
----------

Speed control lever angle

Test data 106961-1877
F:Full speed
----------

----------
a=9deg+-5deg

0000000901

Test data 106961-1877
F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=70mm
----------
a=15deg+-5deg b=33deg+-3deg

Stop lever angle

Test data 106961-1877
N:Pump normal S:Stop the pump.
----------

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

0000001101

Test data 106961-1877
N:Normal B:When boosted
----------

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

0000001501 RACK SENSOR

Test data 106961-1877
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
----------

0000001601 LEVER

Test data 106961-1877
(A) stopper screw Locknut B (C) Bracket (D) Load lever (I) Idle position Mechanical autocruise load lever setting procedure (1)Set the stopper screw after injection pump adjustment. (2)Set the load lever (D) in the idle position and screw in the stopper screw (A) until it contacts lever (D). (3)From the above condition, return screw (A) N turns and fix it using the locknut (B).
----------
N=1~1.5
----------

Timing setting

Test data 106961-1877
(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=12deg
----------
a=(170deg)




Have questions with 106961-1877?





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