106861-1287 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068611287 1156015577


106861-1287 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 106861-1287 1068611287
ISUZU 1156015577 1156015577

Cross reference number

ZEXEL 106861-1287 1068611287
ISUZU 1156015577 1156015577


Zexel num
Bosch num
Firm num
Name
106861-1287 
106861-1288 
 
1156015577  ISUZU
INJECTION-PUMP ASSEMBLY
8PC1 * 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   132424-0620
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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   1-8-7-3- 6-5-4-2
Pre-stroke mm   4 3.97 4.03
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-8
deg.   45 44.75 45.25
Difference between angles 2
Cal 1-7
deg.   90 89.75 90.25
Difference between angles 3
Cal 1-3
deg.   135 134.75 135.25
Difference between angles 4
Cal 1-6
deg.   180 179.75 180.25
Difference between angles 5
Cal 1-5
deg.   225 224.75 225.25
Difference between angles 6
Cal 1-4
deg.   270 269.75 270.25
Difference between angles 7
Cyl.1-2
deg.   315 314.75 315.25
Injection quantity adjustment
Adjusting point   A
Rack position   8.5
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   89.8 88.8 90.8
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   8.7
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   105.7 103.7 107.7
Max. variation between cylinders %   0 -3 3
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   8.5+-0.5
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   108 104 112
Max. variation between cylinders %   0 -3 3
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   D
Rack position   6.8+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   14.5 13.1 15.9
Max. variation between cylinders %   0 -13 13
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_05
Adjusting point   F
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   135 135
Fixing the lever   *
Remarks
When manual lever is on the boost side
 

Test data Ex:

Governor adjustment

Test data 106861-1287
N:Pump speed R:Rack position (mm) (1)Supplied with damper spring not set. (2)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. (3)At excess fuel lever operation: not exceeding EXL (4)Excess fuel setting for starting: SXL
----------
EXL=1.5mm SXL=10.2+-0.1mm
----------

Timer adjustment

Test data 106861-1287
(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=(7deg) 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 106861-1287
F:Full speed
----------

----------
a=10deg+-5deg

0000000901

Test data 106861-1287
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=32deg+-3deg

Stop lever angle

Test data 106861-1287
N:Pump normal S:Stop the pump.
----------

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

0000001101

Test data 106861-1287
N:Normal B:When boosted
----------

----------
a=(5deg) b=(24deg)

0000001501 RACK SENSOR

Test data 106861-1287
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 106861-1287
(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=13deg
----------
a=(170deg)




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