106961-6101 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069616101 1156028391

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106961-6101 1069616101

ISUZU 1156028391 1156028391

Cross reference number

ZEXEL 106961-6101 1069616101

ISUZU 1156028391 1156028391

Zexel num

Bosch num

Firm num

Name

106961-6101
106961-6102

1156028391 ISUZU

INJECTION-PUMP ASSEMBLY
12PD1-N * 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) 134424-4320

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) 134424-4320

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 4.4 4.37 4.43

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. 96.1 94.6 97.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.6

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 96.8 94.8 98.8

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. 101.1 99.1 103.1

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 5.2+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8.8 7.5 10.1

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Damper spring setting
----------

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Timer adjustment

(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.
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L=1-0.2mm N2=800r/min C2=(7)deg t1=1.5--sec. t2=1.5--sec.
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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

F:Full speed
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a=7deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=31deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
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aa=25mm
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a=51deg+-5deg b=64deg+-5deg

0000001301

F:Full load I:Idle (1)Stopper bolt setting
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a=31deg+-3deg b=14.5deg+-5deg

0000001501 RACK SENSOR

Rack sensor adjustment (1)These types of rack sensors do not need adjustment. Confirm the output as described below. (2)Mount the rack sensor main body to the pump main body. (3)Measure the Vist at pump speed N1 and rack position Ra.
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N1=500r/min Ra=8.6mm
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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)-
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aa=8deg
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a=(180deg)