Information injection-pump assembly
ZEXEL
101601-4020
1016014020
ISUZU
5156003706
5156003706
Rating:
Service parts 101601-4020 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-089-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-4020
1016014020
ISUZU
5156003706
5156003706
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
2.4
2.35
2.45
Rack position
Point B R=B
Point B R=B
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
B
Rack position
9.5
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
55.2
53.7
56.7
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
D
Rack position
7
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
7.3
6
8.6
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
58.6
58.6
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
1000+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.9
0.4
1.4
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
2.1
1.6
2.6
Timer adjustment_04
Pump speed
r/min
1650
Advance angle
deg.
3
2.5
3.5
Timer adjustment_05
Pump speed
r/min
-
Advance angle
deg.
5
5
5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)Excess fuel setting for starting: SXL
----------
DL=5.2-0.2mm SXL=9.5+0.2mm
----------
----------
DL=5.2-0.2mm SXL=9.5+0.2mm
----------
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=33deg+-5deg b=30deg+-3deg
----------
----------
a=33deg+-5deg b=30deg+-3deg
Information:
(1) Setscrew. Adjustment for fuel ratio control.(2) Nut. Tighten to a torque of ... 1.70 0.25 N m (15 2 lb in)(3) Lever for manual shutoff.(4) Setscrew. Adjustment for dimension (6).(5) Nut. Tighten to a torque of ... 1.70 0.25 N m (15 2 lb in)(6) Dimension at shutoff. With manual shutoff lever (3) at the maximum shutoff position, the distance from the end of the lever assembly to the face of the rear governor housing must be ... 28.8 0.5 mm (1.13 .02 in) Make sure setscrew (4) is adjusted to give dimension (6) at assembly.(7) Setscrew. This setscrew is used for the adjustment of dimension (6) on engines that use a shutoff detent. Setscrew (7) is not functional on truck engine arrangments. Make sure nut (8) is tightened to the correct torque to hold setscrew (7) in position.(8) Nut. Tighten to a torque of ... 1.70 0.25 N m (15 2 lb in)(9) Broken link spring. See the Miscellaneous Spring Chart.(10) Torque for screws ... 3.4 0.5 N m (31 4 lb in)(11) Spring to center or preload the flyweights. See the Miscellaneous Spring Chart.(12) Dashpot spring. See the Miscellaneous Spring Chart.(13) Governor spring. See the Governor Spring Chart.(14) Overfueling spring (if equipped). See the Miscellaneous Spring Chart.(15) Tighten the insulated terminal in governor housing to a torque of ... 3.4 0.5 N m (31 4 lb in)(16) Setscrew. Adjustment for torque rise setting.(17) Setscrew. Adjustment for fuel setting.(18) Nut. Tighten the nut on setscrews (16) and (17) to a torque of ... 1.70 0.25 N m (15 2 lb in)(19) Bumper spring. See the Miscellaneous Spring Chart. (20) Lever. Install the shutoff lever as illustrated. Angle (A) and angle (B) from the vertical centerline must be ... 30°(21) Guide. The distance from the end of the guide to the housing gasket surface is dimension (C) ... 11.80 0.25 mm (.464 .010 in)