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


101602-0440 INJECTION-PUMP ASSEMBLY
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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

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

Test data 101602-0440
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

Test data 101602-0440
F:Full speed I:Idle (1)Stopper bolt setting
----------

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

Timing setting

Test data 101602-0440
(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)




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