101601-4940 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016014940 1156008153

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101601-4940 1016014940

ISUZU 1156008153 1156008153

Service parts 101601-4940 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2120

3. GOVERNOR 105931-0592

4. SUPPLY PUMP 105220-4781

5. AUTOM. ADVANCE MECHANIS 105612-1670

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder 5-15300-089-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101601-4940 as INJECTION-PUMP ASSEMBLY

106675-4400 as _

Cross reference number

ZEXEL 101601-4940 1016014940

ISUZU 1156008153 1156008153

Zexel num

Bosch num

Firm num

Name

101601-4940

1156008153 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1T * 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 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 1-5-3-6- 2-4

Pre-stroke mm 3.4 3.35 3.45

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 10.7

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 72 71 73

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 H

Rack position 9.6+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9.4 8.1 10.7

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 10.7+-0. 5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 72 71 73

Basic *

Fixing the lever *

Boost pressure kPa 8 8

Boost pressure mmHg 60 60

Injection quantity adjustment_04

Adjusting point B

Rack position 10.85+-0 .5

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 81.9 80.3 83.5

Fixing the lever *

Boost pressure kPa 8 8

Boost pressure mmHg 60 60

Injection quantity adjustment_05

Adjusting point C

Rack position 10.6+-0. 5

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 57.8 56.2 59.4

Fixing the lever *

Boost pressure kPa 8 8 8

Boost pressure mmHg 60 60 60

Injection quantity adjustment_06

Adjusting point I

Rack position 12.8+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 80 80 85

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 10.3

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 10.5

Boost pressure kPa 4.7 4.7 7.4

Boost pressure mmHg 35 35 55

Boost compensator adjustment_03

Pump speed r/min 500 500 500

Rack position 10.6

Remarks
Measure actual boost pressure.

Timer adjustment

Pump speed r/min 1250

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 1 0.1 1

Timer adjustment_03

Pump speed r/min 1350

Advance angle deg. 1 0.5 1.5

Timer adjustment_04

Pump speed r/min 1450

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL (3)Boost pressure: not less than BP1 (4)Boost pressure: not less than BP2 (5)Because the figures in brackets are the target values at torque cam adjustment, perform final adjustment in accordance with governor and injection quantity adjustment standards. (6)Perform governor spring adjustment by setting lever a. (7)After adjustment of the lever a setting, set the lever so that idle set point H can be obtained and confirm standard b. (8)After completing final adjustment, set the lever to obtain J. (9)Next, confirm rack position R1 or more is obtained when rotation is stopped. (10)In this condition, move the lever to the full position and confirm standard c. (excess fuel for starting operation limit). (11)After completing final adjustment, set speed at N1 using lever b. (12)In this condition, after operating the lever to the full position, confirm no excess fuel for starting (black smoke prevention limit). (13)For the excess fuel setting for starting rack position point I, set the lever to obtain standard c in step (10) and then set the rack limit.
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T1=46 RAL=(13)mm BP1=8kPa(60mmHg) BP2=0kPa(0mmHg) R1=11.8mm N1=225r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'b.'
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a=40deg+-5deg b=34deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
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aa=12deg
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a=(20deg)