101602-4651 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016024651 1156021060

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101602-4651 1016024651

ISUZU 1156021060 1156021060

Cross reference number

ZEXEL 101602-4651 1016024651

ISUZU 1156021060 1156021060

Zexel num

Bosch num

Firm num

Name

101602-4651
101602-4652

1156021060 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1T *

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 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 A

Rack position 8

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 72 70.5 73.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 26 26

Boost pressure mmHg 195 195

Injection quantity adjustment_02

Adjusting point B

Rack position 8.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 50.5 48.5 52.5

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point C

Rack position 5.3+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 12.8 11.5 14.1

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 520 520 520

Rack position 8.2

Boost pressure kPa 11.3 6 16.6

Boost pressure mmHg 85 45 125

Boost compensator adjustment_02

Pump speed r/min 520 520 520

Rack position 8.8

Boost pressure kPa 18 16.7 19.3

Boost pressure mmHg 135 125 145

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Boost compensator operation limit position: L1 (3)Set idle sub-spring (4)Main spring setting (5)Rack difference from N = N1
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K=11 L1=(10.5)mm N1=1100r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=2deg+-5deg b=22deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=12deg+-5deg b=46deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
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a=(10deg)