101602-0440 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016020440 5156011220

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101602-0440 1016020440

ISUZU 5156011220 5156011220

Service parts 101602-0440 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-8130

3. GOVERNOR 105410-4460

4. SUPPLY PUMP 105220-4560

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4372

11. Nozzle and Holder 5-15300-103-2

12. Open Pre:MPa(Kqf/cm2) 14.7{150}

13. NOZZLE-HOLDER 105030-3391

14. NOZZLE

105015-3930

15. NOZZLE SET

Include in #1:

101602-0440 as INJECTION-PUMP ASSEMBLY

101609-3230 as _

101609-3231

Cross reference number

ZEXEL 101602-0440 1016020440

ISUZU 5156011220 5156011220

Zexel num

Bosch num

Firm num

Name

101602-0440
101602-0442

5156011220 ISUZU

INJECTION-PUMP ASSEMBLY
6BB1 *

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

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 3.6 3.55 3.65

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 A

Rack position 9.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 52 51 53

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 47.4 45.4 49.4

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.7+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Set idle sub-spring (3)Main spring setting (4)Temporarily set the main spring at N1. After torque control adjustment, set the main spring at N2.
----------
K=4 N1=1250r/min N2=1100+30+20r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=75deg+-5deg b=23deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(90deg)