101901-0680 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1019010680 1156007010

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101901-0680 1019010680

ISUZU 1156007010 1156007010

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Cross reference number

ZEXEL 101901-0680 1019010680

ISUZU 1156007010 1156007010

Zexel num

Bosch num

Firm num

Name

101901-0680

1156007010 ISUZU

INJECTION-PUMP ASSEMBLY
12PB1 * 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 134424-0020

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
R: right hand row, L: left hand row L1R4L9R8 L5R2L11R 10L3R6L7

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Opposite to the driving side NO.1

Difference between angles 1
Cal 1-4 deg. 15 14.5 15.5

Difference between angles 2
Cal 1-9 deg. 60 59.5 60.5

Difference between angles 3
Cal 1-8 deg. 75 74.5 75.5

Difference between angles 4
Cal 1-5 deg. 120 119.5 120.5

Difference between angles 5
Cyl.1-2 deg. 135 134.5 135.5

Difference between angles 6
Cal 1-11 deg. 180 179.5 180.5

Difference between angles 7
Cal 1-10 deg. 195 194.5 195.5

Difference between angles 8
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 9
Cal 1-6 deg. 255 254.5 255.5

Difference between angles 10
Cal 1-7 deg. 300 299.5 300.5

Difference between angles 11
Cal 1-12 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 11.7

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 89.8 87.8 91.8

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 84 83 85

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position 15+-0.5

Pump speed r/min 150 150 150

Each cylinder's injection qty mm3/st. 95 95

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 1050+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 1.4 0.9 1.9

Timer adjustment_03

Pump speed r/min 1250

Advance angle deg. 3 2.5 3.5

Timer adjustment_04

Pump speed r/min 1350

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Rack limit (operating at delivery) (3)Excess fuel setting for starting: SXL
----------
DL=6-0.5mm SXL=12.4+0.2mm
----------

Speed control lever angle

F:Full speed M:Minimum-maximum speed (1)Fix at full speed at delivery. (2)Set the speed at aa. Set using two nuts.
----------
aa=741r/min
----------
a=(9deg) b=(1deg)

0000000901

F:Full load I:Idle S:Stop (1)Rack position aa (pump speed bb r/min )
----------
aa=7.5mm bb=0r/min
----------
a=32deg+-3deg b=13deg+-5deg c=1.5deg+-5deg

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.
Illustration 1 g06602736
Soft Joint
Illustration 2 g06602738
Hard Joint
Refer to Illustration 1 and 2 for updated design from soft joint to hard joint, to mitigate the joint relaxation and air leaks.The new and former part numbers are listed in Table 1.
Table 1
Required Parts
Qty New Part Number Part Name Former Part Number(1)
1 583-3212 Exhaust Bypass 259-1436
(1) The former part number listed is for reference only and may differ.Note: Service parts are not interchangeable between the former and new part number.