106991-1102 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069911102 1156025312


106991-1102 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 106991-1102 1069911102
ISUZU 1156025312 1156025312

Service parts 106991-1102 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106099-9140
3. GOVERNOR 105488-1440
4. SUPPLY PUMP 105237-1390
5. AUTOM. ADVANCE MECHANIS 105693-0220
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:

106991-1102 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106991-1102 1069911102
ISUZU 1156025312 1156025312


Zexel num
Bosch num
Firm num
Name
106991-1102 
106991-1105 
 
1156025312  ISUZU
INJECTION-PUMP ASSEMBLY
12PD1-S *

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   8.9
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   112 110.5 113.5
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   8.45
Pump speed r/min   1150 1150 1150
Average injection quantity mm3/st.   123.7 121.7 125.7
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   4.9+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   8.8 6.8 10.8
Max. variation between cylinders %   0 -13 13
Fixing the rack   *

Test data Ex:

Governor adjustment

Test data 106991-1102
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
----------

Timer adjustment

Test data 106991-1102
(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)deg t1=1.5--sec. t2=1.5--sec.
----------
N1=1100++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=7+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

Test data 106991-1102
F:Full speed
----------

----------
a=7deg+-5deg

0000000901

Test data 106991-1102
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=34.5deg+-3deg

Stop lever angle

Test data 106991-1102
N:Pump normal S:Stop the pump.
----------

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

0000001501 RACK SENSOR

Test data 106991-1102
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.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------

Timing setting

Test data 106991-1102
(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)-
----------
aa=8deg
----------
a=(180deg)




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Group cross 106991-1102 ZEXEL

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1156025312 
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