101603-4900 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034900 1156024042

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-4900 1016034900

ISUZU 1156024042 1156024042

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Cross reference number

ZEXEL 101603-4900 1016034900

ISUZU 1156024042 1156024042

Zexel num

Bosch num

Firm num

Name

101603-4900

1156024042 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 * K

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 131424-0620

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 10.9

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60.3 58.7 61.9

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 325 325 325

Average injection quantity mm3/st. 8.7 7.4 10

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(10.9)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60.3 59.3 61.3

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 65.2 63.6 66.8

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.05

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 64 62.4 65.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1(10.9)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 46.9 45.3 48.5

Fixing the lever *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1300

Advance angle deg. 1.8 1.3 2.3

Timer adjustment_04

Pump speed r/min 1600

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL (3)Actuator operation negative pressure: P1 (4)Actuator operation negative pressure: P2
----------
T1=19 RAL=13.6+0.2mm P1=46.7kPa(350mmHg) P2=0kPa(0mmHg)
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position
----------
aa=45mm
----------
a=19.5deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 1. Adjustment of the aneroid compensator itself and the adjustment after mounting the governor (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in (A) to obtain the performance shown in the graph (to obtain L1). (3)Adjust the (D) spacer so that dimension L2 is obtained. (4)As there is hysterisis, measure when the absolute pressure drops. (5)Hysterisis must not exceed rack position = h1.
----------
N1=1000r/min L1=1.5+-0.5mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.9)mm Rb=R3mm P1=89.8+-2.7kPa(674+-20mmHg) P2=70.1+-0.7kPa(526+-5mmHg) Q1=60.3+-1cm3/1000st Q2=(47.6)+-1.6cm3/1000st

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=14deg
----------
a=(60deg)

Information:

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Some of the 3408E engines and 3412E engines in the above listed machines may experience hard starting or low power due to oil that is leaking past the poppet valve in the injector. The oil leakage is caused by the operating conditions at either low idle or high idle. Excessive oil leakage can reduce actuation pressure to the fuel injector. This may prevent fuel injection.Solution
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Follow the proper troubleshooting procedure for the correct engine. If the problem is not located and the symptoms that are listed above continue, remove the engine valve covers. Electrically disable the injectors. Crank the engine. Watch the spill ports of the injector for oil leakage. A small amount of oil leakage is acceptable. A continuous stream of oil may mean leakage from the poppet valve. Excessive leakage from the poppet valve may prevent fuel injection.Note: Normal oil pressure during cranking should be 5 MPa (725 psi). Oil pressure below 5 MPa (725 psi) may indicate excessive oil leakage in injectors. Do not replace the oil pump. Service personnel should replace the injectors that have a continuous flow of oil from the oil ports. Injectors that have a continuous flow of oil and injectors that are within the guidelines of warranty can be returned. Injectors that do not have a continuous flow of oil should not be replaced. Injectors that do not have a continuous flow of oil should not be returned.Note: For additional information on the operation of Hydraulic Electronic Unit Injectors HEUI, refer to CD, RENR1390.
Illustration 1 g01308874
(1) Oil drain portThe oil drain ports are located underneath the solenoid. This will direct the oil flow downward. Some oil may also leak from the rectangular slots at the side of the solenoid. Excess oil leakage will still be visible on the cylinder head.