Rating:
Information injection-pump assembly
ZEXEL
101603-0290
1016030290
ISUZU
1156017761
1156017761
Cross reference number
ZEXEL
101603-0290
1016030290
ISUZU
1156017761
1156017761
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
13.8
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
89.9
88.3
91.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.7+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
9.4
8.1
10.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.8)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
89.9
88.9
90.9
Basic
*
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.45
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
89.2
86
92.4
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.1
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
83.8
80.6
87
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_06
Adjusting point
D
Rack position
12.6
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
54.5
52.9
56.1
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
15+-0.5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
92
92
100
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
12.6
Boost pressure
kPa
2
2
4.7
Boost pressure
mmHg
15
15
35
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
13.1
Boost pressure
kPa
4.7
4.7
7.4
Boost pressure
mmHg
35
35
55
Boost compensator adjustment_03
Pump speed
r/min
550
550
550
Rack position
R1-0.1
Remarks
Measure actual boost pressure.
Measure actual boost pressure.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
T1=B04 BCL=(1.1)+-0.1mm
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T1=B04 BCL=(1.1)+-0.1mm
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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.
----------
L=1.5+-0.2mm N3=800r/min C3=(6.4)deg t1=2--sec. t2=2--sec.
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N1=1200++r/min N2=1500r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=1.5--deg C2=6.4+-0.3deg R01=0/4load R02=4/4load
----------
L=1.5+-0.2mm N3=800r/min C3=(6.4)deg t1=2--sec. t2=2--sec.
----------
N1=1200++r/min N2=1500r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=1.5--deg C2=6.4+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=43deg+-5deg b=41deg+-3deg
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aa=35mm
----------
a=43deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
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a=25deg+-5deg b=40deg+-5deg
0000001501 RACK SENSOR
(g) rack limit
(h) Standard point
(i) pump end face
(j) Apply red paint.
Rack sensor adjustment (154610-0420)
1. Rack limit adjustment
(1)Fix the rack at the rack limit position Rl.
(2)Attach shim (D) [shim thickness standard (17.5 - R1] to rod (C) and tighten nut (E).
(3)Measure the distance X between the end face of the pump and the nut (E), and select a shim (D) so that X = 33-0.2mm.
(4)Release the rack, mount the joint (B) and fix.
(5)At this time, confirm that the shim (D) does not interfere with the joint (B).
2. Rack limit adjustment (amp-equipped type)
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side and set the pump speed at No r/min.
(3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.)
(4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join.
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N=- R=R1(13.8)mm VR=2+-0.01V
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N=- R=R1(13.8)mm VR=2+-0.01V
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Timing setting
(1)Pump vertical direction
(2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
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a=(60deg)