106961-6095 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069616095 1156030151

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106961-6095 1069616095

ISUZU 1156030151 1156030151

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Cross reference number

ZEXEL 106961-6095 1069616095

ISUZU 1156030151 1156030151

Zexel num

Bosch num

Firm num

Name

106961-6095
106961-6096

1156030151 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 *

Timer adjustment

Pump speed r/min 600--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 550

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 830+-30

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 2 1.5 2.5

Remarks
Measure the actual speed.

Timer adjustment_05

Pump speed r/min 1100

Advance angle deg. 5.5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

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

----------

Speed control lever angle

F:Full speed
----------

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

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=31deg+-3deg

Stop lever angle

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

0000001301

I:Idle F:Full load (1)Stopper bolt setting
----------

----------
a=31deg+-3deg b=14.5deg+-5deg

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)-
----------
aa=8deg
----------
a=(180deg)

Information:

Removal Procedure
Illustration 4 g06465824When Diesel Exhaust Fluid (DEF) lines from the DEF injectors are removed for service, there is a possibility of small DEF quantity to be spilled over the DEF injector body.DEF forms a white, crystalline residue when allowed to dry. This reside can prevent proper sealing of the fittings when the hose is reinstalled. Refer to Illustration 4.DEF Hose Removal Procedure
After the engine is shut off, ensure that the purge cycle is completed before performing the procedure.
Illustration 5 g06465825
Push the hose fitting toward the tube to relieve the force on the hose fitting. Refer to Illustration 5.
Illustration 6 g06465826
Press and hold down the retainer clip button and pull the hose fitting off tube. Refer to Illustration 6.
Illustration 7 g06465828
If hose fitting fails to release, place a compressed air nozzle up against gaps "A" and "B" and blow out dirt and debris for a few seconds on each gap Refer to Illustration 7. Then repeat steps 2 and 3.DEF Hose Cleaning Procedure
Illustration 8 g06465829
DEF and other debris will interfere with the fitting functionality and will prevent sealing of the connector interface. Refer to Illustration 8.
Illustration 9 g06465830
Soak the hose end in distilled water for about a minute. Refer to Illustration 9.
Illustration 10 g06465831
Gently shake the hose dry. Refer to Illustration 10.
Do not use wipes or cloth to wipe the connector. This could introduce fibers into the DEF system and cause DEF pump or DEF injector error codes.DEF Hose Inspection Procedure
Illustration 11 g06465835
Push the end of the retainer clip (D1). Refer to Illustration 11.
Illustration 12 g06465838
Release the force on the clip (D2) to ensure that the clip travels freely. Refer to Illustration 12.
If clip does not travel freely, repeat the DEF hose cleaning procedure.
If clip does not travel freely after two or more cleaning attempts, the clip is damaged and the hose has to be replaced.Installation Procedure of DEF Hose Assembly
Illustration 13 g06465839
Rinse the DEF injector body with distilled water with the electrical connector connected to the injector. Refer to Illustration 13.
Illustration 14 g06465841
Insert the hose into the injector fitting until the retainer clip snaps into place and the tube comes to a stop. Refer to Illustration 14.
Illustration 15 g06465842
Hold the molded portion of the hose and pull away from the injector to ensure it is fully seated and locked in place. Refer to Illustration 15.
If hose does not lock in place and pulls out, the hose end connection or clip has been damaged. Replace the DEF line.