106961-6180 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069616180 1156028152


106961-6180 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 106961-6180 1069616180
ISUZU 1156028152 1156028152

Service parts 106961-6180 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106096-9242
3. GOVERNOR 105488-0431
4. SUPPLY PUMP 105237-1940
5. AUTOM. ADVANCE MECHANIS 105687-0641
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-7192
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 15.7(160)/22.1(225)
13. NOZZLE-HOLDER 105031-4831
14. NOZZLE 105015-6651
15. NOZZLE SET

Include in #1:

106961-6180 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106961-6180 1069616180
ISUZU 1156028152 1156028152


Zexel num
Bosch num
Firm num
Name
106961-6180 
106961-6181 
 
1156028152  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 (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)   134424-3520
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   1-4-9-8- 5-2-11-1 0-3-6-7-
Pre-stroke mm   4 3.97 4.03
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   B
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   C
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   D
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   F
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
 
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.   2.5 2.2 2.8
Load   4/4
Timer adjustment_05
Pump speed r/min   1250
Advance angle deg.   5 5 6
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106961-6180
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)Supplied with damper spring not set. (5)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. (6)At excess fuel lever operation: not exceeding EXL (7)Excess fuel setting for starting: SXL (N = N1)
----------
RT=0.8 TH=2.4mm EXL=2mm SXL=9.2+-0.1mm N1=320r/min
----------

Speed control lever angle

Test data 106961-6180
F:Full speed
----------

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

0000000901

Test data 106961-6180
F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=35mm
----------
a=10deg+-5deg b=33deg+-3deg

Stop lever angle

Test data 106961-6180
N:Pump normal S:Stop the pump.
----------

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

0000001101

Test data 106961-6180
N:Normal B:When boosted
----------

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

Timing setting

Test data 106961-6180
(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)




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