101602-4790 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016024790 1156021830


101602-4790 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101602-4790 1016024790
ISUZU 1156021830 1156021830

Service parts 101602-4790 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-8230
3. GOVERNOR 105410-8780
4. SUPPLY PUMP 105220-4561
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156635-3921
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:

101602-4790 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101602-4790 1016024790
ISUZU 1156021830 1156021830


Zexel num
Bosch num
Firm num
Name
101602-4790 
101602-8110 
 
1156021830  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1 * K 14BE PE6A PE

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   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   8.9
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   56.5 55 58
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   8.6
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   58.8 56.8 60.8
Max. variation between cylinders %   0 -4 4
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   -
Rack position   6.5+-0.5
Pump speed r/min   325 325 325
Average injection quantity mm3/st.   9.4 8 10.8
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 101602-4790
N:Pump speed R:Rack position (mm) (1)Target notch: K
----------
K=6
----------

Speed control lever angle

Test data 101602-4790
F:Full speed I:Idle D:Dead point (1)Stopper bolt setting
----------

----------
a=18deg+-1deg b=20deg+-3deg C=32deg+-5deg

Stop lever angle

Test data 101602-4790
N:Pump normal S:Stop the pump.
----------

----------
a=12deg+-5deg b=46deg+-5deg

0000001501 LEVER

Test data 101602-4790
1. Variable lever adjustment (1)Fix lever (B) in the idle position using bolts (C) and (D). (2)Temporarily fix the lever (A) in the center of the elongated hole. (3)Set the dead point position temporarily and measure the lever angle. (4)Fix the lever (A) at the idle lever angle position using the bolt (E). (5)Lock using bolt (G). (6)After completing idle adjustment, loosen the full side stopper bolt (D). (7)Move the lever (A) in the full speed direction. (8)Fix bolt (D) at full speed position. (9)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
----------

----------

Timing setting

Test data 101602-4790
(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=20deg
----------
a=(90deg)




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