ZEXEL ESPI Cross Reference
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1 ZEXEL ESPI Cross Reference Page 1 Date: Time: 16:07:14 No. Manufacturer No. Manufacturer Name ZEXEL No. BOSCH No. Zexel Alt. No. Parts Name Mark Status Sell Category C600 HINO INJECTION-PUMP ASSEMBLY K C600 TOYOTA INJECTION-PUMP ASSEMBLY K C600 TOYOTA INJECTION-PUMP ASSEMBLY * K C600 HINO INJECTION-PUMP ASSEMBLY * K
2 ZEXEL test values diesel fuel-injection equipment :05:04 Page 1 ZEXEL Ass'y No Bosch Ass'y No Bosch Typecode Engine Type 4B Manufacturer TOYOTA Edition date (2) 1 Adjustment conditions Test oil ISO4113orSAEJ967 d 1404 Test oil P Test oil temperature degc Nozzle Bosch type code NP-DN0SD1510 Nozzle holder P Opening pressure MPa P Opening pressure kgf/cm Injection pipe P Injection pipe mm Inside diameter - outside diameter - length (mm) Joint assembly Tube assembly P Transfer pump pressure kpa P Transfer pump pressure kgf/cm Direction of rotation (viewed from drive side) R Right Checker parts number ECU part number P ECU power supply D.C. V P TCV drive power supply V P TCV drive power supply D.C. Hz Wire harness Intermediate harness Adjustment specification 2.1 Full load delivery S Average injection quantity mm3/st S Difference in delivery mm3/st. 3 3 Full
3 ZEXEL test values diesel fuel-injection equipment :05:04 Page 2 P Boost pressure kpa P Boost pressure mmhg S Average injection quantity mm3/st S Difference in delivery mm3/st. 3 3 CBS S Average injection quantity mm3/st S Difference in delivery mm3/st. 3 3 NA P Pump speed r/min C Average injection quantity mm3/st C Difference in delivery mm3/st. 6 6 P Pump speed r/min C Average injection quantity mm3/st C Difference in delivery mm3/st. 6 6 P Pump speed r/min C Average injection quantity mm3/st P Pump speed r/min C Average injection quantity mm3/st P Pump speed r/min
4 ZEXEL test values diesel fuel-injection equipment :05:04 Page 3 C Average injection quantity mm3/st C Average injection quantity mm3/st Full P Boost pressure kpa P Boost pressure mmhg C Average injection quantity mm3/st P Boost pressure kpa P Boost pressure mmhg C Average injection quantity mm3/st CBS C Average injection quantity mm3/st NA P Pump speed r/min C Average injection quantity mm3/st P Pump speed r/min
5 ZEXEL test values diesel fuel-injection equipment :05:04 Page 4 C Average injection quantity mm3/st P Pump speed r/min C Average injection quantity mm3/st P Pump speed r/min C TCV duty (%) F TCV 60Hz % C Average injection quantity mm3/st C Difference in delivery mm3/st Governing P Pump speed r/min S Average injection quantity mm3/st S Difference in delivery mm3/st. 6 6 P Pump speed r/min C Average injection quantity mm3/st Idle P Pump speed r/min S Average injection quantity mm3/st S Difference in delivery mm3/st. 2 2 P Pump speed r/min C Average injection quantity mm3/st. 3 3
6 ZEXEL test values diesel fuel-injection equipment :05:04 Page 5 P Pump speed r/min C Average injection quantity mm3/st C Difference in delivery mm3/st. 2 2 P Pump speed r/min C Average injection quantity mm3/st P Pump speed r/min C Average injection quantity mm3/st Start P Pump speed r/min S Average injection quantity mm3/st S Difference in delivery mm3/st. 7 7 Full 2.5 Stop P Pump speed r/min C Average injection quantity mm3/st Magnet OFF 2.6 Overflow C Overflow quantity cm3/min Pump chamber pressure
7 ZEXEL test values diesel fuel-injection equipment :05:04 Page 6 S Pressure kpa S Pressure kgf/cm P Pump speed r/min C Pressure kpa C Pressure kgf/cm C Pressure kpa C Pressure kgf/cm P Pump speed r/min C Pressure kpa C Pressure kgf/cm Timer S Timer stroke mm P Pump speed r/min C Timer stroke mm C Timer stroke mm
8 ZEXEL test values diesel fuel-injection equipment :05:04 Page 7 P Pump speed r/min C Timer stroke mm P Pump speed r/min P TCV duty (%) F TCV 60Hz % C Timer stroke mm P Pump speed r/min C Timer stroke mm P Pump speed r/min P TCV duty (%) F TCV 60Hz % C Timer stroke mm TPS output P TCV duty (%) F TCV 60Hz % S TPS output voltage V P TCV duty (%) F TCV 60Hz % C TPS output voltage V C TPS output voltage V P Pump speed r/min
9 ZEXEL test values diesel fuel-injection equipment :05:04 Page 8 P TCV duty (%) F TCV 60Hz % C TPS output voltage V Magnet C Max. applied voltage V P Test voltage V Additional device adjustment Additional device 1 Name POTENTIOMETER ADJUSTMENT N1=1050(r/min) P1=73.3(kPa) P2=550(mmHg) Q1= (mm3/st) V1= (V) V2= (V) V3= (V) Vi=10(V) N1=1050(r/min) Q1= (mm3/st) V1= (V) N = pump speed P = boost pressure Q = injection quantity V = potentiometer C = control lever position B = adjusting point D = check point C1 = idle C2 = full speed A = TCV duty 100% Vi = applied voltage input Adjusting method (dummy bolt method): because the potentiometer is a reverse operation type, u se caution at adjustment. 1. At pump speed N = N1 and injection quantity Q = Q1, hold the dummy bolt against the control l ever and fix using the locknut. At this time move the control lever only from closed to open (idle to full speed). Caution: When it is necessary to return the control lever, first return it once to the idle position an d then perform readjustment. 2. When adjusting the potentiometer, position the control lever against the dummy bolt and adjust the potentiometer so that the output voltage is V1. 3. After completing adjustment remove the dummy bolt. Confirm that the potentiometer output volt age is as specified above at the control lever idle position and full position.
10 ZEXEL test values diesel fuel-injection equipment :05:04 Page Additional device 2 Name STOP LEVER ADJUSTMENT L=4.5~10.6(mm) T=3.4~4.9(Nm)(0.35~0.5(kgfm)) A = adjusting bolt B = locknut C = stop lever Adjusting the stop lever's starting injection quantity At injection quantity adjustment, adjust adjusting bolt A so that the starting injection quantity is as specified. Fix using nut (B) (Tightening torque T). 3 Assembly dimension S K dimension mm S KF dimension mm S MS dimension mm S BCS stroke mm S Pre-stroke mm S Control lever angle alpha deg S Control lever angle beta deg
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104742-3100 ZEXEL test values diesel fuel-injection equipment 2009/05/25 11:52:46 Page 1 ZEXEL Ass'y No. 104742-3100 Bosch Ass'y No. F 01G 09W 0EH Bosch Typecode Engine Type S4S-DT Manufactures MITSUBISHI
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101481-0154 ZEXEL test values diesel fuel-injection equipment 2009/12/04 23:17:48 Page 1 ZEXEL Ass'y No. 101481-0154 Bosch Ass'y No. 9 400 611 742 Bosch Typecode Engine Type 4BD2 Manufactures ISUZU Edition
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