106961-1915 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069611915 1156021716

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106961-1915 1069611915

ISUZU 1156021716 1156021716

Cross reference number

ZEXEL 106961-1915 1069611915

ISUZU 1156021716 1156021716

Zexel num

Bosch num

Firm num

Name

106961-1915
106961-1916

1156021716 ISUZU

INJECTION-PUMP ASSEMBLY
12PC1 * 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) 134424-3520

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 1-4-9-8- 5-2-11-1 0-3-6-7-

Pre-stroke mm 4 3.97 4.03

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-4 deg. 15 14.75 15.25

Difference between angles 2
Cal 1-9 deg. 60 59.75 60.25

Difference between angles 3
Cal 1-8 deg. 75 74.75 75.25

Difference between angles 4
Cal 1-5 deg. 120 119.75 120.25

Difference between angles 5
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 6
Cal 1-11 deg. 180 179.75 180.25

Difference between angles 7
Cal 1-10 deg. 195 194.75 195.25

Difference between angles 8
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 9
Cal 1-6 deg. 255 254.75 255.25

Difference between angles 10
Cal 1-7 deg. 300 299.75 300.25

Difference between angles 11
Cal 1-12 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 -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 1 0.5 1

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min (1075)

Advance angle deg. 1 0.5 1

Timer adjustment_04

Pump speed r/min 1150

Advance angle deg. 2.5 2.2 2.8

Timer adjustment_05

Pump speed r/min 1250

Advance angle deg. 5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Supplied with damper spring not set. (2)Tolerance for racks not indicated: +-0.05mm. (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 (N = N1)
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EXL=2mm SXL=9.2+-0.1mm N1=320r/min
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Speed control lever angle

F:Full speed M:Minimum-maximum speed (1)Set the pump speed at aa (2)Set the pump speed at bb. (3)Set using 2 nuts (at delivery).
----------
aa=(1380)r/min bb=(722)r/min
----------
a=9deg+-5deg b=(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)