108622-1150 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086221150 1156032901

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108622-1150 1086221150

ISUZU 1156032901 1156032901

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Cross reference number

ZEXEL 108622-1150 1086221150

ISUZU 1156032901 1156032901

Zexel num

Bosch num

Firm num

Name

108622-1150
108622-1151

1156032901 ISUZU

INJECTION-PUMP ASSEMBLY
6WA1-TC * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131424-7120

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 32

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 6.4 6.37 6.43

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 14.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 216 214 218

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 6.5+-0.5

Pump speed r/min 370 370 370

Average injection quantity mm3/st. 15 11.8 18.2

Max. variation between cylinders % 0 -13 13

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_03

Adjusting point A

Rack position R1(14.5)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 216 214 218

Basic *

Fixing the lever *

Boost pressure kPa 58.7 58.7

Boost pressure mmHg 440 440

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R2-2.2

Boost pressure kPa 21.3 20 22.6

Boost pressure mmHg 160 150 170

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R2(R1+0. 15)

Boost pressure kPa 45.3 45.3 45.3

Boost pressure mmHg 340 340 340

0000001601

Pre-stroke mm 6.4 6.37 6.43

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 8.5 8 9

Remarks
When the eccentric pin is tightened

_03

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 4 3.95 4.05

Output voltage V 2.45 2.44 2.46

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 6.4 6.37 6.43

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_05

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 3.4

Output voltage V 3 2.98 3

Confirmation *

_06

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

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. (3)Boost compensator stroke: BCL (4)Damper spring setting
----------
T1=AG18 BCL=2.2+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=1.5deg+-5deg b=35.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=0r/min cc=1+-0.3mm
----------
a=18deg+-5deg b=44deg+-5deg

0000001301

(1)Pump vertical direction (2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
----------
aa=5deg bb=6.4+-0.03mm
----------
a=(100deg)

0000001901

A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------

----------

0000002201 RACK SENSOR

G:Red paint H:Pump end face P/N: part number of suitable shim (1)Threaded type rack block (2)Welded type rack block Rack sensor adjustment 1. Threaded type rack sensor (-5*20, P type, no TICS rack limit). (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the pump lever. (3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1. (4)Fix using the nut (F). (5)Affix the caution plate to the upper part of the joint (B). (6)Apply (G) at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the end surface of the pump (H) and the joint (B) 2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads. Screw in to the end from (the position where the bobbin (A) is rotated 9 turns). Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=R1(14.5)+0.95mm N1=1000r/min V1=3+-0.01V
----------

Information:

* Remove any carbon deposits from the injection nozzles before disassembling, assembling, or adjusting the injection nozzle assembly. Before disassembling, check the pressure and shape of the spray and inspect the assembly for fuel leakage. Do not disassemble if no defects are evident.* Do not change the needle valve and nozzle combination on each cylinder.
* Assembly sequenceFollow the disassembly sequence in reverse.Service standards Tightening torque (Unit: N m {kgf m}) Special tools (Unit: mm) Inspection before removal
Inspection: Injection nozzle* Connect the injection nozzle to the nozzle tester and carry out the following inspections.
* Before starting the inspections, operate the lever on the nozzle tester two or three times to bleed out all the air.
(1) Checking the valve opening pressure* Push down the lever on the nozzle tester at a rate of one to two seconds per stroke. This will cause the pressure gauge reading to rise gradually, and the needle will suddenly deflect. Note the pressure at which the needle starts to deflect. * If the measurement is out of the standard value range, disassemble the nozzle, clean it, and then adjust it using an adjusting shim.* Available adjusting shims (thickness): 1.2 mm to 1.7 mm (11 different thicknesses in increments of 0.05 mm)* If the valve opening pressure is still incorrect after the adjustment, replace the injection nozzle assembly.
* Do not touch the spray that comes out of the nozzle.
(2) Inspecting the spray condition * Pump the lever on the nozzle at a rate of about one to two seconds per stroke and keep it spraying continuously.A Spray in the form of straight line (Good: spray angle at 10° or less)B Spray angle too large (Bad)C Spray deviates from centerline (Bad)D Irregular spray (Bad)
* Do not touch the spray that comes out of the nozzle.
* Check that no fuel drips from the nozzle after the spray is complete.* If defects are evident, disassemble and clean the injection nozzle, and then inspect its spray condition once again.* If defects persist after reinspection, replace the injection nozzle assembly.(3) Checking for leakage * Decrease the nozzle pressure to a pressure 1960 kPa {20 kgf/cm2} lower than the first valve opening pressure. Maintain this pressure for 10 seconds and check that no fuel drips from the end of the nozzle.* If fuel drips are evident, disassemble and clean the injection nozzle, and then perform a leakage test once again.* If leakage is detected during the reinspection, replace the injection nozzle assembly.Removal procedure
Removal: Injection nozzle
* Do not touch the sliding surfaces of the needle valve. If you accidentally touch it, clean it with a cleaning fluid (such as gas oil).* Do not change the needle valve and nozzle combination on each cylinder.
Cleaning procedure
Cleaning: Injection nozzle* Wash the needle valve and nozzle in a cleaning fluid (such as gas oil), then use
to remove any carbon deposits according to the following procedure. * Remove carbon deposits from the tip of the needle valve using the clean bar of
.
* Do not use a wire brush