106961-1542 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069611542 1156022294

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106961-1542 1069611542

ISUZU 1156022294 1156022294

Cross reference number

ZEXEL 106961-1542 1069611542

ISUZU 1156022294 1156022294

Zexel num

Bosch num

Firm num

Name

106961-1542
106961-1543

1156022294 ISUZU

INJECTION-PUMP ASSEMBLY
10PC1 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

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 255 221 289

Overflow valve opening pressure (drive side) kgf/cm2 2.6 2.25 2.95

Overflow valve (governor side) 134424-2720

Overflow valve opening pressure (governor side) kPa 255 221 289

Overflow valve opening pressure (governor side) kgf/cm2 2.6 2.25 2.95

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 4.4 4.37 4.43

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 7.9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 87.4 85.9 88.9

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.9

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 94.5 90.5 98.5

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 5.2+-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 F

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 -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0.5 0.3 0.8

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min (950)

Advance angle deg. 0.5 0.3 0.8

Timer adjustment_04

Pump speed r/min 1050

Advance angle deg. 3 2.7 3.3

Timer adjustment_05

Pump speed r/min 1150

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Supplied with damper spring not set. (2)Supplied with torque spring not set. (3)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. (4)At excess fuel lever operation: not exceeding EXL (5)Excess fuel setting for starting: SXL
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EXL=2mm SXL=9+-0.1mm
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Speed control lever angle

F:Full speed
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----------
a=6deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=33deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=60deg+-5deg b=73deg+-5deg

0000001101

N:Normal B:When boosted
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----------
a=(5deg) b=(24deg)

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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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=12deg
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a=(170deg)