Information injection-pump assembly
ZEXEL
101601-8863
1016018863
ISUZU
1156017423
1156017423
Rating:
Cross reference number
ZEXEL
101601-8863
1016018863
ISUZU
1156017423
1156017423
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
131424-4920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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
11.5
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
73.4
71.8
75
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(11.5)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
73.4
72.4
74.4
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
I
Rack position
14+-0.5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
90
90
98
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1350--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
2
1.5
2.5
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=C73
----------
----------
T1=C73
----------
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=42deg+-5deg b=35deg+-3deg
----------
aa=35mm
----------
a=42deg+-5deg b=35deg+-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)
Information:
13. Install spring (16), bellcrank (17), and retaining ring (15) on cover assembly (14). 14. Install gasket (24) bellcrank assembly (14) and two bolts (13) on timing advance housing. 15. Install timing advance housing (11) on the timing gear cover. Remove the screwdriver. 16. Check the position (protrusion) of ball detent (25) in tool (B). It should protrude only slightly into the grooved area. During the following steps, tool (B) and the area of installation cannot be seen. The cutaway views are shown for better photo illustration. 17. Install tool (B) with grooved side toward the engine, between the power piston bearing and bellcrank (17) so that ear (26) is in an approximate 9 o'clock position. 18. Apply a slight hand pressure and push tool (B) towards the engine and rotate counterclockwise slowly until ear (27) is in an approximately 9 o'clock position. A slight resistance as the tool starts to seat can be felt.19. Continue to rotate tool (B) counterclockwise until ear (27) is in an approximate 6 o'clock position. 20. Carefully install timing position sensor (6), spring (28), damping washer (29), bracket (8), collar (10) and locknut (9). Do not tighten locknut (9) at this time.21. Connect the wiring harness from the timing position sensor to the wiring harness on the engine. (J2/P2 connector). Be sure that the harness from the PEEC control module is connected to the engine wiring harness. (J7/P7 connector)22. Disconnect the PEEC data link connector (the short pigtail out of the top of the PEEC control module - J4/P4 connector) from the truck wiring harness and connect either tool (C) or tool (D) to the PEEC data link connector (J8 connector).23. Turn power on the PEEC control module. Select "Timing Position Sensor Calibration" from the main menu of tool (C) or (D). See Special Instructions, Form No's. SEHS8742 and/or SEHS8743.
Do not engage the starter, or damage to the engine will be the result.
24. Adjust collar (10) on timing position sensor until the bar graph on tool (C) or (D) is centered and indicate the timing position sensor is calibrated.25. Tighten locknut (9) to 55 7 N m (41 5 lb.ft.).26. Check the timing position calibration reading on tool (C) or (D) to insure that the timing position sensor is still in calibration after tightening the locknut.27. Turn off power to the PEEC control module.28. Disconnect tool (C) or (D) from the PEEC control module. Connect the PEEC data link connector (J1 connector) to the truck harness (P1 connector).29. Remove tool (B) from between the power piston and the bellcrank.30. Use tool (E) to rotate the engine in the clockwise direction to release the pressure on tool (F). Remove tool (F). 31. Lubricate o-ring seal (31) with engine oil and install on timing solenoid (5).32. Install timing solenoid (5) into the timing advance housing. Be sure lever (32) is engaged in the groove of the sleeve. Access port (33) has been provided to visually check the position of lever (32). 33.
Do not engage the starter, or damage to the engine will be the result.
24. Adjust collar (10) on timing position sensor until the bar graph on tool (C) or (D) is centered and indicate the timing position sensor is calibrated.25. Tighten locknut (9) to 55 7 N m (41 5 lb.ft.).26. Check the timing position calibration reading on tool (C) or (D) to insure that the timing position sensor is still in calibration after tightening the locknut.27. Turn off power to the PEEC control module.28. Disconnect tool (C) or (D) from the PEEC control module. Connect the PEEC data link connector (J1 connector) to the truck harness (P1 connector).29. Remove tool (B) from between the power piston and the bellcrank.30. Use tool (E) to rotate the engine in the clockwise direction to release the pressure on tool (F). Remove tool (F). 31. Lubricate o-ring seal (31) with engine oil and install on timing solenoid (5).32. Install timing solenoid (5) into the timing advance housing. Be sure lever (32) is engaged in the groove of the sleeve. Access port (33) has been provided to visually check the position of lever (32). 33.