106961-1509 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069611509 1156032111

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106961-1509 1069611509

ISUZU 1156032111 1156032111

Service parts 106961-1509 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106096-9302

3. GOVERNOR 105488-0452

4. SUPPLY PUMP 105237-1940

5. AUTOM. ADVANCE MECHANIS 105687-0631

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:

106961-1509 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106961-1509 1069611509

ISUZU 1156032111 1156032111

Zexel num

Bosch num

Firm num

Name

106961-1509
106961-6220

1156032111 ISUZU

INJECTION-PUMP ASSEMBLY
10PC1 * K 14CE PE10P PE

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 255 255 255

Overflow valve opening pressure (drive side) kgf/cm2 2.6 2.6 2.6

Overflow valve (governor side) 134424-2720

Overflow valve opening pressure (governor side) kPa 255 255 255

Overflow valve opening pressure (governor side) kgf/cm2 2.6 2.6 2.6

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 8.1

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 B

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 C

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 E

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. 3 2.7 3.3

Load 4/4

Timer adjustment_05

Pump speed r/min 1250

Advance angle deg. 6 5.5 6.5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

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)Deliver with damper spring not operating. (5)At excess fuel lever operation: not exceeding EXL (6)Excess fuel setting for starting: SXL (N = N1) (7)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.
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RT=0.8 TH=2.4mm EXL=2mm SXL=9.2+-0.1mm N1=320r/min
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Speed control lever angle

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

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

0000000901

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

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

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

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=12deg
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a=(170deg)