106991-1022 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069911022 1156025002

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106991-1022 1069911022

ISUZU 1156025002 1156025002

Service parts 106991-1022 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106099-9100

3. GOVERNOR 105488-1281

4. SUPPLY PUMP 105237-1390

5. AUTOM. ADVANCE MECHANIS 105687-0310

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7851

11. Nozzle and Holder 1-15300-204-1

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

13. NOZZLE-HOLDER 105031-4831

14. NOZZLE

105015-8200

15. NOZZLE SET

Include in #1:

106991-1022 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106991-1022 1069911022

ISUZU 1156025002 1156025002

Zexel num

Bosch num

Firm num

Name

106991-1022
106991-1025

1156025002 ISUZU

INJECTION-PUMP ASSEMBLY
12PD1-C *

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) 134424-4020

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) 134424-4020

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 4.2 4.17 4.23

Rack position
Point A R=A

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 8.3

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 107.8 106.3 109.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 109.4 107.4 111.4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.9

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 116.9 114.9 118.9

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 4.8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8.7 7.4 10

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Timer adjustment

Pump speed r/min 600--

Advance angle deg. 0 0 0

Load 4/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 550

Advance angle deg. 0.3

Load 4/4

Timer adjustment_03

Pump speed r/min 800+-30

Advance angle deg. 2 1.5 2.5

Load 4/4

Timer adjustment_04

Pump speed r/min 900

Advance angle deg. 2 1.5 2.5

Load 3/4

Timer adjustment_05

Pump speed r/min 1100

Advance angle deg. 5.5 5 6

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)Damper spring setting
----------
RT=0.8 TH=2.1mm
----------

Speed control lever angle

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

----------
a=6deg+-5deg

0000000901

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

----------
a=10deg+-5deg b=33deg+-3deg

Stop lever angle

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

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

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 (set timing) (4)-
----------

----------
a=(180deg)