106871-1013 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068711013 1156014583

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106871-1013 1068711013

ISUZU 1156014583 1156014583

Service parts 106871-1013 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP

3. GOVERNOR

4. SUPPLY PUMP 105237-1390

5. AUTOM. ADVANCE MECHANIS 105693-0050

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7012

11. Nozzle and Holder 1-15300-141-1

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.1{225}

13. NOZZLE-HOLDER 105031-3842

14. NOZZLE 105015-5780

15. NOZZLE SET

Include in #1:

106871-1013 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-1013 1068711013

ISUZU 1156014583 1156014583

Zexel num

Bosch num

Firm num

Name

106871-1013
106871-1012

1156014583 ISUZU

INJECTION-PUMP ASSEMBLY
8PC1-T *

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 1-8-7-3- 6-5-4-2

Pre-stroke mm 4.2 4.17 4.23

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25

Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 8.5

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 102.8 100.8 104.8

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Boost pressure kPa 22.7 22.7

Boost pressure mmHg 170 170

Injection quantity adjustment_02

Adjusting point B

Rack position 9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 103.4 101.9 104.9

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 22.7 22.7

Boost pressure mmHg 170 170

Injection quantity adjustment_03

Adjusting point C

Rack position 6.2+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 14.5 13.1 15.9

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Injection quantity adjustment_04

Adjusting point E

Rack position 12+-0.5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 134.3 134.3 144.3

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Set the excess lever.

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 8.7

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 9

Boost pressure kPa 9.3 9.3 9.3

Boost pressure mmHg 70 70 70

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)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. (2)Excess fuel lever setting (3)Boost compensator stroke (4)Set the torque spring. (5)Beginning of damper spring operation: DL
----------
DL=4.4-0.5mm
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Timer adjustment

(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=(5.375)deg t1=1.5--sec. t2=1.5--sec.
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N1=950++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=5.375+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
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----------
a=10deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=36deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

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

0000001101

N:Normal B:When boosted
----------

----------
a=(5deg) b=(16deg)

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

Timing setting

(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)-
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aa=11deg
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a=(170deg)