Information injection-pump assembly
ZEXEL
101606-0140
1016060140
ISUZU
8976000811
8976000811
Rating:
Cross reference number
ZEXEL
101606-0140
1016060140
ISUZU
8976000811
8976000811
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
105780-8260
Bosch type code
9 430 610 133
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
18
Opening pressure
kgf/cm2
184
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-8620
Overflow valve opening pressure
kPa
206
172
240
Overflow valve opening pressure
kgf/cm2
2.1
1.75
2.45
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.8
3.75
3.85
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor 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
14.5
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
133.5
131.9
135.1
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
Z
Rack position
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
15.5
14.2
16.8
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(14.5)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
133.5
132.5
134.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
(R1+0.65
)+0.05-0
.15
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
127
123.8
130.2
Fixing the lever
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=N11
----------
----------
T1=N11
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C2=(8deg) t1=2--sec. t2=2--sec.
----------
N1=1300++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
----------
L=1.5+-0.2mm N2=800r/min C2=(8deg) t1=2--sec. t2=2--sec.
----------
N1=1300++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
(2)Use the pin at R = aa
(3)Viewed from feed pump side.
----------
aa=35mm
----------
a=10deg+-5deg b=40deg+-3deg
----------
aa=35mm
----------
a=10deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
0000001501 RACK SENSOR
Rack sensor adjustment
1. Flange type rack sensor (rack sensor adjustment -5*20)
(1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures.
(2)Mount the rack sensor main body to the pump main body.
(3)Fix the pump lever at full.
(4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist.
(5)Move the pump lever two or three times.
(6)Set again to full.
(7)Confirm that the amplifier output voltage is Vist.
(8)Fix the caution plate to the upper part of the rack sensor.
(For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.)
(9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=850r/min Ra=R1(14.5)mm Vist=3.74+-0.28V
----------
----------
V1=5+-0.01V N1=850r/min Ra=R1(14.5)mm Vist=3.74+-0.28V
----------
Timing setting
(1)Pump vertical direction
(2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=6deg
----------
a=(160deg)
----------
aa=6deg
----------
a=(160deg)
Information:
You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.Before proceeding with Every 50 Hour maintenance, perform all Daily maintenance requirements.Dust Collector
Never run the engine without an air cleaner installed. Never run the engine with a damaged air cleaner. Do not use filter elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaners prevent airborne debris from entering the engine through the air inlet.
Clean
Typical two stage air cleaner. Individual applications may be different.1. Remove the air cleaner cap (1). Remove the dust collector cup (2).2. Wipe dust collector cup with a clean, dry cloth.3. Install the cup. Install and secure the cap. If equipped with a heavy duty air cleaner: refer to the Heavy Duty Air Cleaner topic in the Daily section of this manual for information about cleaning the dust collector cup.Light Duty Air Cleaner (If Equipped)
Light duty air cleaners are not serviceable (washable). Light duty air cleaners are intended for a 50 service hours of maximum use, or one year, whichever occurs first. However, engines operating in a severe environment may require more frequent air cleaner replacement.Dust conditions vary for different operating environments. Service the air cleaner at regular intervals as determined by the operating environment. Check the air cleaner service indicator (if equipped) daily.Check the air cleaner for cleanliness and damage such as rips and tears. Replace the air cleaner element at the required service interval, or more often as determined by the operating environmental dust conditions. To Replace the Light Duty Air Cleaner Element: 1. Loosen the clamp (2) fastening the air cleaner element (1) to the air inlet, and remove the dirty element and clamp.2. Install the clamp on a new element.3. Install the new element to the air inlet and tighten the clamp.
Never run the engine without an air cleaner installed. Never run the engine with a damaged air cleaner. Do not use filter elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaners prevent airborne debris from entering the engine through the air inlet.
Clean
Typical two stage air cleaner. Individual applications may be different.1. Remove the air cleaner cap (1). Remove the dust collector cup (2).2. Wipe dust collector cup with a clean, dry cloth.3. Install the cup. Install and secure the cap. If equipped with a heavy duty air cleaner: refer to the Heavy Duty Air Cleaner topic in the Daily section of this manual for information about cleaning the dust collector cup.Light Duty Air Cleaner (If Equipped)
Light duty air cleaners are not serviceable (washable). Light duty air cleaners are intended for a 50 service hours of maximum use, or one year, whichever occurs first. However, engines operating in a severe environment may require more frequent air cleaner replacement.Dust conditions vary for different operating environments. Service the air cleaner at regular intervals as determined by the operating environment. Check the air cleaner service indicator (if equipped) daily.Check the air cleaner for cleanliness and damage such as rips and tears. Replace the air cleaner element at the required service interval, or more often as determined by the operating environmental dust conditions. To Replace the Light Duty Air Cleaner Element: 1. Loosen the clamp (2) fastening the air cleaner element (1) to the air inlet, and remove the dirty element and clamp.2. Install the clamp on a new element.3. Install the new element to the air inlet and tighten the clamp.