106961-1497 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069611497 1156027380


 

Information injection-pump assembly

ZEXEL 106961-1497 1069611497
ISUZU 1156027380 1156027380
106961-1497 INJECTION-PUMP ASSEMBLY
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Service parts 106961-1497 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106096-9311
3. GOVERNOR 105488-0534
4. SUPPLY PUMP 105237-1940
5. AUTOM. ADVANCE MECHANIS 105693-0191
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-7192
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 15.7(160)/22.1(225)
13. NOZZLE-HOLDER 105031-4831
14. NOZZLE 105015-6651
15. NOZZLE SET

Include in #1:

106961-1497 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106961-1497 1069611497
ISUZU 1156027380 1156027380


Zexel num
Bosch num
Firm num
Name
106961-1497 
106961-1498 
 
1156027380  ISUZU
INJECTION-PUMP ASSEMBLY
10PC1 * 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)   134424-3520
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)   134424-2720
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   1-8-7-6- 5-4-3-10 -9-2
Pre-stroke mm   4 3.97 4.03
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-8
deg.   27 26.75 27.25
Difference between angles 2
Cal 1-7
deg.   72 71.75 72.25
Difference between angles 3
Cal 1-6
deg.   99 98.75 99.25
Difference between angles 4
Cal 1-5
deg.   144 143.75 144.25
Difference between angles 5
Cal 1-4
deg.   171 170.75 171.25
Difference between angles 6
Cal 1-3
deg.   216 215.75 216.25
Difference between angles 7
Cal 1-10
deg.   243 242.75 243.25
Difference between angles 8
Cal 1-9
deg.   288 287.75 288.25
Difference between angles 9
Cyl.1-2
deg.   315 314.75 315.25
Injection quantity adjustment
Adjusting point   B
Rack position   8.1
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   85.6 84.1 87.1
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   7.9+-0.5
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   95.9 91.9 99.9
Max. variation between cylinders %   0 -3 3
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   5.4+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   8 6.6 9.4
Max. variation between cylinders %   0 -13 13
Fixing the rack   *
Injection quantity adjustment_04
Adjusting point   F
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   137 137
Fixing the lever   *
Remarks
When manual lever is on the boost side
 
Injection quantity adjustment_05
Adjusting point   G
Rack position   8.1
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   94.8 90.8 98.8
Max. variation between cylinders %   0 -3 3
Fixing the lever   *

Test data Ex:

Governor adjustment

Test data 106961-1497
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=2mm SXL=9.2+-0.1mm
----------

Timer adjustment

Test data 106961-1497
(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 106961-1497
F:Full speed
----------

----------
a=9deg+-5deg

0000000901

Test data 106961-1497
F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=35mm
----------
a=10deg+-5deg b=33deg+-3deg

Stop lever angle

Test data 106961-1497
N:Pump normal S:Stop the pump.
----------

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

0000001101

Test data 106961-1497
N:Normal B:When boosted
----------

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

0000001501 RACK SENSOR

Test data 106961-1497
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 106961-1497
(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=12deg
----------
a=(170deg)




Information:


Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.
Total Base Number (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines
The Total Base Number (TBN) for an oil depends on the fuel sulfur level. For direct injection engines that use distillate fuel, the minimum TBN must be 10 times the fuel sulfur level. The TBN is determined by the "ASTM D2896" procedure. The minimum TBN of the oil is 5 regardless of a low fuel sulfur level. Illustration 1 demonstrates the TBN.
Illustration 1 g00104890
(Y) TBN by "ASTM D2896"
(X) Percentage of fuel sulfur by weight
(1) TBN of new oil
(2) Change the used oil when the TBN reaches this level. Use the following guidelines for fuel sulfur levels that exceed 1.5 percent:
Choose an oil with the highest TBN that meets one of these classifications:
API CG-4
API CH-4
API CI-4Note: API CH-4 oils and API CI-4 oils are acceptable if the requirements of Caterpillar's ECF-1 (Engine Crankcase Fluid specification-1) are met. CH-4 oils and CI-4 oils that have not met the requirements of Caterpillar's ECF-1 Specification may cause reduced engine life.
Reduce the oil change interval. Base the oil change interval on the oil analysis. Ensure that the oil analysis includes the condition of the oil and a wear metal analysis. Excessive piston deposits can be produced by an oil with a high TBN. These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore.
Operating Direct Injection (DI) diesel engines with fuel sulfur levels over 1.0 percent may require shortened oil change intervals in order to help maintain adequate wear protection.
Lubricant Viscosity Recommendations for Direct Injection (DI) Diesel Engines
The proper SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation. Refer to Table 1 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.Refer to Table 1 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.Note: Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up.If ambient temperature conditions at engine start-up require the use of multigrade SAE 0W oil, SAE 0W-40 viscosity grade is generally preferred over SAE 0W-20 or SAE 0W-30.Note: SAE 10W-30 is the preferred viscosity grade for the following diesel engines when the ambient temperature is above −18 °C (0 °F), and below 40 °C (104 °F).
C7
C-9
C9
3116
3126When an engine is started and an engine is operated in ambient temperatures below −20 °C (−4 °F), use multigrade oils that are capable of flowing in low temperatures.These oils have lubricant viscosity grades of SAE 0W or SAE 5W.When an engine is started and operated in ambient temperatures below −30 °C (−22 °F), use a synthetic base stock multigrade oil with a 0W viscosity grade or with a 5W viscosity grade. Use an oil with a

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