106991-1024 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069911024 1156025004

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106991-1024 1069911024

ISUZU 1156025004 1156025004

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Buy INJECTION-PUMP ASSEMBLY 106991-1024 zexel genuine, new aftermarket engine parts with delivery

Service parts 106991-1024 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106099-9100

3. GOVERNOR 105488-1281

4. SUPPLY PUMP 105237-1940

5. AUTOM. ADVANCE MECHANIS 105687-0311

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7851

11. Nozzle and Holder 1-15300-204-1

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.1{225}

13. NOZZLE-HOLDER 105031-4831

14. NOZZLE

105015-8200

15. NOZZLE SET

Include in #1:

106991-1024 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106991-1024 1069911024

ISUZU 1156025004 1156025004

Zexel num

Bosch num

Firm num

Name

106991-1024
106991-1025

1156025004 ISUZU

INJECTION-PUMP ASSEMBLY
12PD1-C * 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) 134424-4020

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) 134424-4020

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 4.2 4.17 4.23

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. 107.8 106.3 109.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 109.4 107.4 111.4

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. 116.9 114.9 118.9

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 4.8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8.7 7.4 10

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 800+-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)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Damper spring setting
----------
RT=0.8 TH=2.1mm
----------

Speed control lever angle

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

----------
a=6deg+-5deg

0000000901

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

----------
a=10deg+-5deg b=33deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

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

6. Coat the seal of the element with a thin film of clean engine oil or antifreeze. 7. Install the element. Tighten it until the seal contacts the base, then tighten it an additional 3/4 turn. 8. Open the inlet valve and the outlet valve. 9. Maintain the coolant level above the low level plate. 10. Clean and install the radiator cap.11. Start the engine and check for leaks.Brakes
Inspect - Adjust
The machine must be level, the bowl lowered, and the parking brake applied.1. Block the wheels securely.2. Start the engine. 3. When the air pressure reaches the NORMAL range, stop the engine. 4. Release the parking/emergency brake. 5. Measure the distance from the rotochamber to the slack adjuster clevis retaining pin. 6. Apply the service brake and measure the amount of travel of the rod. If the travel is 76 mm (3 inches) or more, adjust the brake.7. Measure the brake rotochamber rod travel of all four wheel brakes. Scraper rotochambers are located inside the push frame.To Adjust
1. Loosen the adjustment locking bolt. 2. Turn the adjusting bolt, as required, until the travel is 41 mm (1.62 inches). 3. Tighten the locking bolt. 4. Apply and release the brakes, watching the rotochamber rod for binding.5. Observe the diaphragm for leaks. 6. Start the engine and allow air pressure to reach 690 kPa (100 psi) or in the green range on the air pressure gauge.7. Apply the parking brake.8. Stop the engine.9. Remove the blocking from the wheels.Check the Air System for Leaks
1. Start the engine and allow air pressure to reach 690 kPa (100 psi) or in the green range on the air pressure gauge. 2. Apply the service brakes and hold them in the applied condition.3. Stop the engine.4. With the brakes applied, watch the air pressure gauge.5. The pressure should drop no more than 35 kPa (5 psi) in 10 minutes.6. If the air pressure loss is greater than 35 kPa (5 psi), inspect the air lines and connections. Make any necessary repairs.To Test Brakes
Be sure the area around the vehicle is clear of personnel and obstructions.Fasten the seat belt before operating the vehicle.Test the brakes on a dry, level surface.
The vehicle must be on a dry, level surface, the bowl lowered and the parking brake applied.The following tests are to determine if the service brake or parking/emergency brake is functional. These tests are not intended to measure maximum brake holding effort.Brake holding effort required to hold a vehicle at a specific engine rpm will vary from vehicle to vehicle due to differences in engine setting, power train efficiency, etc., as well as differences in brake holding ability.Engine rpm at beginning of vehicle movement, with service or parking/emergency brake applied, should be compared against the engine rpm your specific vehicle was able to hold on a prior test, as an indication of system deterioration.Service Brake
1. Start the engine. Allow the engine to reach the normal operating temperature.2. When air pressure registers 690 kPa (100 psi) or