Information injection-pump assembly
ZEXEL
101602-4110
1016024110
ISUZU
1156014453
1156014453
Rating:
Service parts 101602-4110 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-103-2
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}
15.
NOZZLE SET
Cross reference number
ZEXEL
101602-4110
1016024110
ISUZU
1156014453
1156014453
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
1-5-3-6-
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
A
Rack position
9.8
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
58
57
59
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.8
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
55
51
59
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.7+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
9.4
8.1
10.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Main spring setting
(3)Set idle sub-spring
----------
K=4
----------
----------
K=4
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=77deg+-5deg b=22deg+-5deg
----------
----------
a=77deg+-5deg b=22deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=46deg+-5deg
----------
----------
a=12deg+-5deg b=46deg+-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=22deg
----------
a=(90deg)
----------
aa=22deg
----------
a=(90deg)
Information:
Condition: DEF nozzle does not shut off, causing DEF to exit the tank breather
Troubleshooting Steps:
Machine should be parked on level surface during DEF fill. Parking the machine with front end running at a downward angle may cause DEF to exit breather before the float in the tank valve rises enough to shut off nozzle.
Verify that the pressure at the nozzle from supply pump meets minimum 172 to 200 kPa (25 to 29 psi) requirement to trigger nozzle shut off.
Inspect tank-mounted valve for debris or ice preventing closure.
Inspect nozzle for damage from rough handling, DEF crystal buildup. Replace or repair as needed.Condition: DEF Nozzle shuts off before tank is full
Troubleshooting Steps:
Machine should be parked on level surface during DEF fill. Parking the machine with front end running at an upward angle may cause DEF Nozzle to shut off prematurely because DEF level at the rear of the tank near valve may cause float to rise and shut off nozzle.
Verify that flow at nozzle does not exceed the recommended target of 45 L/min (12 US gpm).
Excessive flow can damage tank-mounted valve and cause premature shut off.
Inspect vent line going up to breather and breather for any blockage, clean or replace if needed.
Inspect DEF fast fill line from receiver to valve, the valve for any blockages. Clean or replace if needed.
Inspect nozzle for damage from rough handling, DEF crystal buildup. Repair or replace as needed.
Troubleshooting Steps:
Machine should be parked on level surface during DEF fill. Parking the machine with front end running at a downward angle may cause DEF to exit breather before the float in the tank valve rises enough to shut off nozzle.
Verify that the pressure at the nozzle from supply pump meets minimum 172 to 200 kPa (25 to 29 psi) requirement to trigger nozzle shut off.
Inspect tank-mounted valve for debris or ice preventing closure.
Inspect nozzle for damage from rough handling, DEF crystal buildup. Replace or repair as needed.Condition: DEF Nozzle shuts off before tank is full
Troubleshooting Steps:
Machine should be parked on level surface during DEF fill. Parking the machine with front end running at an upward angle may cause DEF Nozzle to shut off prematurely because DEF level at the rear of the tank near valve may cause float to rise and shut off nozzle.
Verify that flow at nozzle does not exceed the recommended target of 45 L/min (12 US gpm).
Excessive flow can damage tank-mounted valve and cause premature shut off.
Inspect vent line going up to breather and breather for any blockage, clean or replace if needed.
Inspect DEF fast fill line from receiver to valve, the valve for any blockages. Clean or replace if needed.
Inspect nozzle for damage from rough handling, DEF crystal buildup. Repair or replace as needed.