Information injection-pump assembly
ZEXEL
101602-4203
1016024203
ISUZU
1156016572
1156016572
Rating:
Cross reference number
ZEXEL
101602-4203
1016024203
ISUZU
1156016572
1156016572
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
A
Rack position
8.1
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
43.4
39.4
47.4
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
40.6
39.6
41.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
6.5+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
7.5
6.2
8.8
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)RACK LIMIT: RAL
(3)Set idle sub-spring
(4)Main spring setting
----------
K=6 RAL=13.5+-0.2mm
----------
----------
K=6 RAL=13.5+-0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=2deg+-5deg b=20deg+-5deg
----------
----------
a=2deg+-5deg b=20deg+-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=20deg
----------
a=(90deg)
----------
aa=20deg
----------
a=(90deg)
Information:
Removal Procedure
Illustration 4 g06465824When Diesel Exhaust Fluid (DEF) lines from the DEF injectors are removed for service, there is a possibility of small DEF quantity to be spilled over the DEF injector body.DEF forms a white, crystalline residue when allowed to dry. This reside can prevent proper sealing of the fittings when the hose is reinstalled. Refer to Illustration 4.DEF Hose Removal Procedure
After the engine is shut off, ensure that the purge cycle is completed before performing the procedure.
Illustration 5 g06465825
Push the hose fitting toward the tube to relieve the force on the hose fitting. Refer to Illustration 5.
Illustration 6 g06465826
Press and hold down the retainer clip button and pull the hose fitting off tube. Refer to Illustration 6.
Illustration 7 g06465828
If hose fitting fails to release, place a compressed air nozzle up against gaps "A" and "B" and blow out dirt and debris for a few seconds on each gap Refer to Illustration 7. Then repeat steps 2 and 3.DEF Hose Cleaning Procedure
Illustration 8 g06465829
DEF and other debris will interfere with the fitting functionality and will prevent sealing of the connector interface. Refer to Illustration 8.
Illustration 9 g06465830
Soak the hose end in distilled water for about a minute. Refer to Illustration 9.
Illustration 10 g06465831
Gently shake the hose dry. Refer to Illustration 10.
Do not use wipes or cloth to wipe the connector. This could introduce fibers into the DEF system and cause DEF pump or DEF injector error codes.DEF Hose Inspection Procedure
Illustration 11 g06465835
Push the end of the retainer clip (D1). Refer to Illustration 11.
Illustration 12 g06465838
Release the force on the clip (D2) to ensure that the clip travels freely. Refer to Illustration 12.
If clip does not travel freely, repeat the DEF hose cleaning procedure.
If clip does not travel freely after two or more cleaning attempts, the clip is damaged and the hose has to be replaced.Installation Procedure of DEF Hose Assembly
Illustration 13 g06465839
Rinse the DEF injector body with distilled water with the electrical connector connected to the injector. Refer to Illustration 13.
Illustration 14 g06465841
Insert the hose into the injector fitting until the retainer clip snaps into place and the tube comes to a stop. Refer to Illustration 14.
Illustration 15 g06465842
Hold the molded portion of the hose and pull away from the injector to ensure it is fully seated and locked in place. Refer to Illustration 15.
If hose does not lock in place and pulls out, the hose end connection or clip has been damaged. Replace the DEF line.
Illustration 4 g06465824When Diesel Exhaust Fluid (DEF) lines from the DEF injectors are removed for service, there is a possibility of small DEF quantity to be spilled over the DEF injector body.DEF forms a white, crystalline residue when allowed to dry. This reside can prevent proper sealing of the fittings when the hose is reinstalled. Refer to Illustration 4.DEF Hose Removal Procedure
After the engine is shut off, ensure that the purge cycle is completed before performing the procedure.
Illustration 5 g06465825
Push the hose fitting toward the tube to relieve the force on the hose fitting. Refer to Illustration 5.
Illustration 6 g06465826
Press and hold down the retainer clip button and pull the hose fitting off tube. Refer to Illustration 6.
Illustration 7 g06465828
If hose fitting fails to release, place a compressed air nozzle up against gaps "A" and "B" and blow out dirt and debris for a few seconds on each gap Refer to Illustration 7. Then repeat steps 2 and 3.DEF Hose Cleaning Procedure
Illustration 8 g06465829
DEF and other debris will interfere with the fitting functionality and will prevent sealing of the connector interface. Refer to Illustration 8.
Illustration 9 g06465830
Soak the hose end in distilled water for about a minute. Refer to Illustration 9.
Illustration 10 g06465831
Gently shake the hose dry. Refer to Illustration 10.
Do not use wipes or cloth to wipe the connector. This could introduce fibers into the DEF system and cause DEF pump or DEF injector error codes.DEF Hose Inspection Procedure
Illustration 11 g06465835
Push the end of the retainer clip (D1). Refer to Illustration 11.
Illustration 12 g06465838
Release the force on the clip (D2) to ensure that the clip travels freely. Refer to Illustration 12.
If clip does not travel freely, repeat the DEF hose cleaning procedure.
If clip does not travel freely after two or more cleaning attempts, the clip is damaged and the hose has to be replaced.Installation Procedure of DEF Hose Assembly
Illustration 13 g06465839
Rinse the DEF injector body with distilled water with the electrical connector connected to the injector. Refer to Illustration 13.
Illustration 14 g06465841
Insert the hose into the injector fitting until the retainer clip snaps into place and the tube comes to a stop. Refer to Illustration 14.
Illustration 15 g06465842
Hold the molded portion of the hose and pull away from the injector to ensure it is fully seated and locked in place. Refer to Illustration 15.
If hose does not lock in place and pulls out, the hose end connection or clip has been damaged. Replace the DEF line.