101602-4641 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016024641 1156021381

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101602-4641 1016024641

ISUZU 1156021381 1156021381

Service parts 101602-4641 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-8970

3. GOVERNOR

4. SUPPLY PUMP 105220-5400

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156637-1820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7621

11. Nozzle and Holder 1-15300-227-1

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.1{225}

13. NOZZLE-HOLDER 105030-3231

14. NOZZLE 105015-7710

15. NOZZLE SET

Include in #1:

101602-4641 as INJECTION-PUMP ASSEMBLY

Include in #2:

104748-1420 as _

Cross reference number

ZEXEL 101602-4641 1016024641

ISUZU 1156021381 1156021381

Zexel num

Bosch num

Firm num

Name

101602-4641
101602-4642

1156021381 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1MTC *

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 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 4.4 4.35 4.45

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 A

Rack position 10.9

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 125.4 123.8 127

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 100 100

Boost pressure mmHg 750 750

Injection quantity adjustment_02

Adjusting point -

Rack position 6.1+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 9.2

Boost pressure kPa 12 10.7 13.3

Boost pressure mmHg 90 80 100

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 10.9

Boost pressure kPa 80 80 80

Boost pressure mmHg 600 600 600

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Set idle sub-spring (3)Main spring setting (4)Boost compensator stroke
----------
K=10
----------

Speed control lever angle

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

----------
a=11deg+-5deg b=29deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)Use the hole above R = cc
----------
aa=0r/min bb=1-0.2mm cc=40mm
----------
a=32deg+-5deg b=(55deg)

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=(15deg44min)
----------
a=(90deg)