106693-1630 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066931630 1156019981

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106693-1630 1066931630

ISUZU 1156019981 1156019981

Cross reference number

ZEXEL 106693-1630 1066931630

ISUZU 1156019981 1156019981

Zexel num

Bosch num

Firm num

Name

106693-1630
106693-1634

1156019981 ISUZU

INJECTION-PUMP ASSEMBLY
6QA2 *

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 134424-1920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-4-2-6- 3-5

Pre-stroke mm 3 2.97 3.03

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

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

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

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

Injection quantity adjustment

Adjusting point A

Rack position 6.8

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 118 116 120

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.4

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 97.7 95.7 99.7

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point -

Rack position 4.2+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 13 9.8 16.2

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_04

Adjusting point E

Rack position 7.7+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 109.6 106.6 112.6

Fixing the lever *

Remarks
After startup boost setting

Injection quantity adjustment_05

Adjusting point F

Rack position 7.2+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 101.4 98.4 104.4

Timer adjustment

Pump speed r/min 900+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 5.5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Excess fuel setting for starting: SXL (2)Damper spring setting: DL
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SXL=(7.7)+-0.1mm DL=3.3-0.5mm
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Speed control lever angle

F:Full speed
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a=5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Attach the return spring to the bottom hole and adjust.
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a=(26deg)+-3deg b=55deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=52deg+-5deg b=64deg+-5deg

0000001501 RACK SENSOR

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.
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V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
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0000001601 MICRO SWITCH

Switch adjustment Adjust the bolt so that the lower lever position is obtained when the switch is turned ON. (1)Speed N1 (2)Rack position Ra
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N1=325r/min Ra=3.8mm
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0000001701 GOVERNOR TORQUE CONTROL

Dr:Torque control stroke (A): Without torque control spring capsule 1. Adjustment procedures (1)Procedure is the same as that for the RFD (former type), except that the positive torque control stroke must be determined at the full lever setting. 2. Procedures for adjustment (1)Remove the torque control spring capsule. (2)Operate the pump at approximately N1. (End of idling spring operation < N1.) (3)Tilt the lever to the full side. (4)Set so that R = RF. (5)Increase the speed by pushing in the screw (attached to the bracket on the rear of the tension lever) through the adjusting window. (6)Adjust so that the torque control stroke Dr1 can be obtained. (7)Align N2 and N3 with the torque control spring capsule. 3. Final confirmation (1)After final confirmation, temporarily set the load lever to N = N1, R = idling position. (2)From this condition, increase speed to N = N4. (3)Confirm that positive torque control stroke is Dr2.
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N1=500r/min N2=600+-30r/min N3=(850)r/min N4=1100r/min RF=6.6mm RI=3.8mm Dr1=0.6mm Dr2=0+0.3mm
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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)-
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aa=14deg
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a=(60deg)