Rating:
Information injection-pump assembly
ZEXEL
101603-4490
1016034490
ISUZU
1156022670
1156022670
Cross reference number
ZEXEL
101603-4490
1016034490
ISUZU
1156022670
1156022670
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 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
14
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
98.2
96.6
99.8
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
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(14)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
98.2
97.2
99.2
Basic
*
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.7
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
90.5
87.3
93.7
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.3
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
85.4
82.2
88.6
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1-1.65
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
49.3
46.1
52.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
90
90
98
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
(R1-0.3)
-1.35
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
(R1-0.3)
-0.85
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
R1-0.3
Remarks
Measure actual boost pressure.
Measure actual boost pressure.
Timer adjustment
Pump speed
r/min
1325--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1275
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
1
0.5
1.5
Remarks
Finish
Finish
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=C49 BCL=1.35+-0.1mm
----------
----------
T1=C49 BCL=1.35+-0.1mm
----------
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=40deg+-3deg
----------
aa=35mm
----------
a=43deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=13deg
----------
a=(60deg)
----------
aa=13deg
----------
a=(60deg)