106961-1040 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069611040 1156014561

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106961-1040 1069611040

ISUZU 1156014561 1156014561

Service parts 106961-1040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106096-9110

3. GOVERNOR 105488-8720

4. SUPPLY PUMP 105237-1390

5. AUTOM. ADVANCE MECHANIS 105693-0060

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7003

11. Nozzle and Holder 1-15300-138-2

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

13. NOZZLE-HOLDER 105031-4831

14. NOZZLE

105015-6250

15. NOZZLE SET

Include in #1:

106961-1040 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106961-1040 1069611040

ISUZU 1156014561 1156014561

Zexel num

Bosch num

Firm num

Name

106961-1040
106961-1048

1156014561 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 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 1-8-7-6- 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 8.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 89.8 88.3 91.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 105.7 103.7 107.7

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.5+-0.5

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 108 104 112

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 6.8+-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 *

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

Injection quantity adjustment_05

Adjusting point F

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 135 135

Fixing the lever *

Remarks
When manual lever is on the boost side

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)Supplied with damper spring not set. (3)At excess fuel lever operation: not exceeding EXL (4)Excess fuel setting for starting: SXL
----------
EXL=1.5mm SXL=10.2+-0.1mm
----------

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=(7.5)deg t1=1.5--sec. t2=1.5--sec.
----------
N1=1100++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=7.5+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
----------

----------
a=10deg+-5deg

0000000901

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

----------
a=10deg+-5deg b=32deg+-3deg

Stop lever angle

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

----------
a=36deg+-5deg b=73deg+-3deg

0000001101

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

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

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)-
----------
aa=13deg
----------
a=(170deg)