Information injection-pump assembly
ZEXEL
101491-0400
1014910400
ISUZU
8943177780
8943177780
Rating:
Cross reference number
ZEXEL
101491-0400
1014910400
ISUZU
8943177780
8943177780
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
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
1-3-4-2
Pre-stroke
mm
3.4
3.35
3.45
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
10.2
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
53.8
52.2
55.4
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
300
300
300
Average injection quantity
mm3/st.
9.5
8
11
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(10.2)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
53.8
52.8
54.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.1
Pump speed
r/min
1800
1800
1800
Average injection quantity
mm3/st.
52.9
49.7
56.1
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
42.8
39.6
46
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+0.7
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
43.5
39.5
47.5
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
56
48
64
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1300--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1250
Advance angle
deg.
0.6
Timer adjustment_03
Pump speed
r/min
1900
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
----------
T1=A49
----------
----------
T1=A49
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=5.5deg+-5deg b=37deg+-3deg
----------
----------
a=5.5deg+-5deg b=37deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=45deg+-5deg b=40deg+-5deg
----------
----------
a=45deg+-5deg b=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=15deg
----------
a=(90deg)
----------
aa=15deg
----------
a=(90deg)
Information:
Use of the Pickup During Wet Conditions
If the pickup becomes wet, it may operate intermittently or not at all. Although the pickup is water resistant, it is not waterproof. Water spray from rain or other sources may cause the pickup to stop producing an output signal.If this happens, the pickup should be removed from the engine and allowed to dry out thoroughly. If necessary, the pickup can be dried in an oven at approximately 50°C (122°F). After drying, the pickup should operate correctly.If it is not possible to keep the pickup dry, use the following procedure: If the pickup must be used during wet conditions, it may be possible to protect it from moisture by using a water displacing spray such as WD-40®.Remove the pickup from the engine. Thoroughly spray the pickup from all directions. Make sure the pickup is completely covered with the spray. Reinstall the pickup on the engine and check its operation.When water first contacts the pickup, the unit may stop working temporarily, but will start working again after the water has been displaced by the solution. If necessary, spray the solution on the pickup after installation on the injection line.Permanent Installation on the Engine
If the pickup is to be permanently installed on the engine, install the pickup on the fuel injection line in the usual manner. Make sure that the thumbscrew is hand tightened securely, but not over tightened. Run the engine and check the operation of the pickup.Make sure that the pickup and line are clean and dry. If the pickup is working correctly, use a can of spray paint to thoroughly paint the pickup from all directions. Several coats should be applied. Let the paint dry thoroughly before operating the engine.Checking the Operation of the Amplifier and Pickup
(1) 6V2100 Multitach. (2) 5P9698 Calibrator. (3) 5P7366 Power Cable. (4) Digital Multimeter. (5) Screwdriver. (6) 6V6152 Adapter. Screwdriver (5) should have a blade approximately 150 mm (6 in) long with 6 mm (.25 in) diameter shaft of round bare metal (not anodized or insulated).The 6V6152 Adapter (6) is a phono plug-to-BNC connector. Modifications must be made to the 5P9698 Calibrator (2). Refer to Special Instruction, SMHS7504-01.Checking the 4C6812 Amplifier
(1) 6V6152 Adapter Plug. (2) 5P9698 Calibrator. (3) 4C6812 Amplifier. (4) Connector. (5) 5P7366 Power Cable. (6) Knob. (7) Battery Indicator. (8) No Input Signal Light.1. Install 6V6152 Adapter Plug (1) on the end of the output cable on 5P9698 Calibrator (2). Plug the adapter into 4C6812 Amplifier (3).2. Check the operation of the multitach being used by performing the CHECKING PHOTO OPERATION test procedure contained in Special Instruction SEHS7807. (This is to ensure it is operating correctly on PHOTO operation.)3. Plug connector (4), on the end of the amplifier output cable, into the PH (photo) connector on the multitach. Attach 5P7366 Power Cable (5) to the multitach and to a suitable power source. Refer to SEHS7807.4. Program the multitach for .5 P/REV and to read R/MIN on the PH (photo) input. Turn knob (6) on
If the pickup becomes wet, it may operate intermittently or not at all. Although the pickup is water resistant, it is not waterproof. Water spray from rain or other sources may cause the pickup to stop producing an output signal.If this happens, the pickup should be removed from the engine and allowed to dry out thoroughly. If necessary, the pickup can be dried in an oven at approximately 50°C (122°F). After drying, the pickup should operate correctly.If it is not possible to keep the pickup dry, use the following procedure: If the pickup must be used during wet conditions, it may be possible to protect it from moisture by using a water displacing spray such as WD-40®.Remove the pickup from the engine. Thoroughly spray the pickup from all directions. Make sure the pickup is completely covered with the spray. Reinstall the pickup on the engine and check its operation.When water first contacts the pickup, the unit may stop working temporarily, but will start working again after the water has been displaced by the solution. If necessary, spray the solution on the pickup after installation on the injection line.Permanent Installation on the Engine
If the pickup is to be permanently installed on the engine, install the pickup on the fuel injection line in the usual manner. Make sure that the thumbscrew is hand tightened securely, but not over tightened. Run the engine and check the operation of the pickup.Make sure that the pickup and line are clean and dry. If the pickup is working correctly, use a can of spray paint to thoroughly paint the pickup from all directions. Several coats should be applied. Let the paint dry thoroughly before operating the engine.Checking the Operation of the Amplifier and Pickup
(1) 6V2100 Multitach. (2) 5P9698 Calibrator. (3) 5P7366 Power Cable. (4) Digital Multimeter. (5) Screwdriver. (6) 6V6152 Adapter. Screwdriver (5) should have a blade approximately 150 mm (6 in) long with 6 mm (.25 in) diameter shaft of round bare metal (not anodized or insulated).The 6V6152 Adapter (6) is a phono plug-to-BNC connector. Modifications must be made to the 5P9698 Calibrator (2). Refer to Special Instruction, SMHS7504-01.Checking the 4C6812 Amplifier
(1) 6V6152 Adapter Plug. (2) 5P9698 Calibrator. (3) 4C6812 Amplifier. (4) Connector. (5) 5P7366 Power Cable. (6) Knob. (7) Battery Indicator. (8) No Input Signal Light.1. Install 6V6152 Adapter Plug (1) on the end of the output cable on 5P9698 Calibrator (2). Plug the adapter into 4C6812 Amplifier (3).2. Check the operation of the multitach being used by performing the CHECKING PHOTO OPERATION test procedure contained in Special Instruction SEHS7807. (This is to ensure it is operating correctly on PHOTO operation.)3. Plug connector (4), on the end of the amplifier output cable, into the PH (photo) connector on the multitach. Attach 5P7366 Power Cable (5) to the multitach and to a suitable power source. Refer to SEHS7807.4. Program the multitach for .5 P/REV and to read R/MIN on the PH (photo) input. Turn knob (6) on