Information injection-pump assembly
ZEXEL
101603-8120
1016038120
ISUZU
1156028220
1156028220
Rating:
Cross reference number
ZEXEL
101603-8120
1016038120
ISUZU
1156028220
1156028220
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
9.9
Pump speed
r/min
1350
1350
1350
Average injection quantity
mm3/st.
139.6
138
141.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
107
107
Boost pressure
mmHg
800
800
Injection quantity adjustment_02
Adjusting point
B
Rack position
4.4+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
15.6
14.3
16.9
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
8
Boost pressure
kPa
40
37.3
42.7
Boost pressure
mmHg
300
280
320
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
(9.9)
Boost pressure
kPa
93.3
93.3
93.3
Boost pressure
mmHg
700
700
700
Timer adjustment
Pump speed
r/min
1350++
Advance angle
deg.
0
0
0
Remarks
Do not advance until starting N = 1350/
Do not advance until starting N = 1350/
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
1
1
1
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure)
(3)Set idle sub-spring
(4)Main spring setting
(5)Boost compensator stroke
----------
K=13 L1=11.1+-0.1mm
----------
----------
K=13 L1=11.1+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=26deg+-5deg b=32deg+-5deg
----------
----------
a=26deg+-5deg b=32deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.2mm
----------
a=32deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.2mm
----------
a=32deg+-5deg b=(55deg)
0000001101
N:Normal
B:When boosted
(1)Rack position = aa
----------
aa=11.1+-0.1mm
----------
a=(15deg) b=(29deg)
----------
aa=11.1+-0.1mm
----------
a=(15deg) b=(29deg)
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=11deg
----------
a=(60deg)
----------
aa=11deg
----------
a=(60deg)
Information:
start by:a) remove pistons1. Check to make sure that all coolant has been removed from the cylinder block.2. Put covers on the crankshaft journals for protection from dirt and water. 3. Make an adjustment of the legs on tool (A) for the length of the cylinder liner. Be careful not to damage the piston cooling tube at the bottom of the cylinder liner.4. Install tool (A) and remove the cylinder liner. 5. Remove filler band (2) and O-ring seals (1) from the cylinder liner.Install Cylinder Liners
1. Clean the cylinder liners and liner bores in the block.2. Install the liners in the block without seals or filler bands.3. Check the cylinder liner projection as follows: a) Install the 3/4"-16 NF bolts and 2F126 Washers of tooling (A) on the spacer plate around each cylinder liner as shown. Tighten the bolts evenly in four steps. 1. Tighten to a torque of 10 lb.ft. (14 N m).2. Tighten to a torque of 25 lb.ft. (35 N m).3. Tighten to a torque of 50 lb.ft. (70 N m).4. Tighten to a torque of 70 lb.ft. (95 N m).b) Put the adapter plate and one plate of tooling (A) on top of the liner and install the remainder of tooling (A). Be sure the crossbar is in position at the center of the liner. Tighten the bolts that hold tooling (A) evenly in four steps:1. Tighten to a torque of 5 lb.ft. (7 N m).2. Tighten to a torque of 15 lb.ft. (20 N m).3. Tighten to a torque of 25 lb.ft. (35 N m).4. Tighten to a torque of 50 lb.ft. (70 N m).c) Check to be sure the distance from the bottom edge of the bar to the top of the cylinder block is the same on both sides of the cylinder liner.d) Check the cylinder liner projection with tooling (B) at four locations around the cylinder liner. See the Specifications Section for the correct liner projection.
1. Clean the cylinder liners and liner bores in the block.2. Install the liners in the block without seals or filler bands.3. Check the cylinder liner projection as follows: a) Install the 3/4"-16 NF bolts and 2F126 Washers of tooling (A) on the spacer plate around each cylinder liner as shown. Tighten the bolts evenly in four steps. 1. Tighten to a torque of 10 lb.ft. (14 N m).2. Tighten to a torque of 25 lb.ft. (35 N m).3. Tighten to a torque of 50 lb.ft. (70 N m).4. Tighten to a torque of 70 lb.ft. (95 N m).b) Put the adapter plate and one plate of tooling (A) on top of the liner and install the remainder of tooling (A). Be sure the crossbar is in position at the center of the liner. Tighten the bolts that hold tooling (A) evenly in four steps:1. Tighten to a torque of 5 lb.ft. (7 N m).2. Tighten to a torque of 15 lb.ft. (20 N m).3. Tighten to a torque of 25 lb.ft. (35 N m).4. Tighten to a torque of 50 lb.ft. (70 N m).c) Check to be sure the distance from the bottom edge of the bar to the top of the cylinder block is the same on both sides of the cylinder liner.d) Check the cylinder liner projection with tooling (B) at four locations around the cylinder liner. See the Specifications Section for the correct liner projection.