108621-1020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086211020 1156028030


108621-1020 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 108621-1020 1086211020
ISUZU 1156028030 1156028030

Cross reference number

ZEXEL 108621-1020 1086211020
ISUZU 1156028030 1156028030


Zexel num
Bosch num
Firm num
Name
108621-1020 
108621-1021 
 
1156028030  ISUZU
INJECTION-PUMP ASSEMBLY
6WA1-TCC * 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   131424-7120
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure 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
RED3 control unit part number   407910-3 960
RED3 rack sensor specifications mm   19
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   32
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-5-3-6- 2-4
Pre-stroke mm   8.5 8.47 8.53
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.75 60.25
Difference between angles 2
Cal 1-3
deg.   120 119.75 120.25
Difference between angles 3
Cal 1-6
deg.   180 179.75 180.25
Difference between angles 4
Cyl.1-2
deg.   240 239.75 240.25
Difference between angles 5
Cal 1-4
deg.   300 299.75 300.25
Injection quantity adjustment
Rack position   (11.9)
Vist V   2.06 2.06 2.06
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   172 170 174
Max. variation between cylinders %   0 -3 3
Basic   *
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   8.4+-0.0 3
Remarks
Refer to items regarding the pre-stroke actuator
 
Injection quantity adjustment_02
Rack position   (6.6)
Vist V   2.9 2.8 3
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   16.3 13.1 19.5
Max. variation between cylinders %   0 -13 13
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   8.4+-0.0 3
Governor adjustment
Pump speed r/min   850--
Advance angle deg.   0 0 0
Load   3/4
Remarks
Start
 
Governor adjustment_02
Pump speed r/min   800
Advance angle deg.   0.3
Load   3/4
Governor adjustment_03
Pump speed r/min   1000
Advance angle deg.   3 2.5 3.5
Load   4/4
Remarks
Finish
 
0000001201
Pre-stroke mm   8.5 8.47 8.53
Remarks
When the timing sleeve is pushed up
 
_02
Connector angle deg.   8.5 8 9
Remarks
When the eccentric pin is tightened
 
_03
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   6.1 6.05 6.15
Output voltage V   2.45 2.44 2.46
Adjustment   *
_04
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   8.5 8.47 8.53
Output voltage V   1.2 1 1.4
Confirmation   *
Remarks
Output voltage V1
 
_05
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   5.5
Output voltage V   3 2.98 3
Confirmation   *
_06
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Output voltage V   3.05 3.05
Confirmation of operating range   *

Test data Ex:

Speed control lever angle

Test data 108621-1020
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=1mm bb=20mm
----------
a=17deg+-5deg b=37deg+-5deg

0000000901

Test data 108621-1020
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
----------
aa=5deg bb=8.5+-0.03mm
----------
a=(100deg)

0000001501

Test data 108621-1020
A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------

----------

0000001701

Test data 108621-1020
(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 19 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Group cross 108621-1020 ZEXEL

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