101901-4230 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1019014230 1156012140

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101901-4230 1019014230

ISUZU 1156012140 1156012140

Cross reference number

ZEXEL 101901-4230 1019014230

ISUZU 1156012140 1156012140

Zexel num

Bosch num

Firm num

Name

101901-4230
101901-4232

1156012140 ISUZU

INJECTION-PUMP ASSEMBLY
8PB1T *

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 132424-0620

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
R: right hand row, L: left hand row 1L-8R-7L -3L-6R-5 L-4R-2R

Pre-stroke mm 4.4 4.35 4.45

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

Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-4 deg. 270 269.5 270.5

Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 12

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 106.3 104.3 108.3

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 101.3 101.3

Boost pressure mmHg 760 760

Injection quantity adjustment_02

Adjusting point B

Rack position 12.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 111.3 110.3 112.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 101.3 101.3

Boost pressure mmHg 760 760

Injection quantity adjustment_03

Adjusting point C

Rack position 12.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 109.5 107.5 111.5

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 101.3 101.3

Boost pressure mmHg 760 760

Injection quantity adjustment_04

Adjusting point D

Rack position 8.2+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 16.7 15.3 18.1

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 80.3 80.3

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point G

Rack position 12.6

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 116.2 113.7 118.7

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 101.3 101.3

Boost pressure mmHg 760 760

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 11.3

Boost pressure kPa 10.7 9.4 12

Boost pressure mmHg 80 70 90

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 12.1

Boost pressure kPa 15.3 14 20.6

Boost pressure mmHg 115 105 155

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Boost compensator stroke
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DL=7-0.5mm
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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=1-0.2mm N2=800r/min C2=3.8+-0.3deg t1=0.7--sec. t2=0.7--sec.
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N1=1000++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=3.8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed M:Minimum-maximum speed (1)At delivery (2)Pump speed = aa
----------
aa=500r/min
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a=8deg+-5deg b=8deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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----------
a=1.5deg+-5deg b=(28deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=40deg+-5deg b=71deg+-5deg

0000001501 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
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V1= 5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
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0000001601 LEVER

(A) Load lever (B) Stopper bolt (C) Full load stopper bolt (D) Load lever (E) Cancel lever position (F) Full load lever position (G) Pin (part of control lever) Cancel lever stopper bolt adjustment procedure (1)The position where the load lever (A) contacts the full load stopper bolt (C) determines the full load position. (2)Move the load lever (D) in the full direction. (3)Move lever (D) so that it separates from lever (A). (4)Moved a~b from the full load position. (5)Set so that lever (D), pin (G) and stopper bolt (B) contact and fix the bolt (B).
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a=3deg b=5deg
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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=11deg
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a=(40deg)