106681-1001 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066811001 1156031141

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106681-1001 1066811001

ISUZU 1156031141 1156031141

Service parts 106681-1001 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-3020

3. GOVERNOR 105923-2191

4. SUPPLY PUMP 105237-5060

5. AUTOM. ADVANCE MECHANIS 105682-0140

6. COUPLING PLATE 105664-0860

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4581

11. Nozzle and Holder 1-15300-357-0

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105041-3081

14. NOZZLE 105025-1120

15. NOZZLE SET

Include in #1:

106681-1001 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106681-1001 1066811001

ISUZU 1156031141 1156031141

Zexel num

Bosch num

Firm num

Name

106681-1001
106681-1002

1156031141 ISUZU

INJECTION-PUMP ASSEMBLY
6WA1-TC * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 134424-4320

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3 2.97 3.03

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 13

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 196 194 198

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 6.5+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 15 11.8 18.2

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 196 194 198

Basic *

Fixing the lever *

Boost pressure kPa 46 46

Boost pressure mmHg 345 345

Injection quantity adjustment_04

Adjusting point B

Rack position R1(13)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 168.5 162.5 174.5

Fixing the lever *

Boost pressure kPa 46 46

Boost pressure mmHg 345 345

Boost compensator adjustment

Pump speed r/min 420 420 420

Rack position R2-2.6

Boost pressure kPa 10 8.7 11.3

Boost pressure mmHg 75 65 85

Boost compensator adjustment_02

Pump speed r/min 420 420 420

Rack position R2(R1-1. 6)

Boost pressure kPa 32.7 32.7 32.7

Boost pressure mmHg 245 245 245

Timer adjustment

Pump speed r/min 925--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 875

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 975

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL (4)Damper spring setting
----------
T1=AE64 BCL=2.6+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=1.5deg+-5deg b=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=0r/min cc=1+-0.3mm
----------
a=18deg+-5deg b=44deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(90deg)