101602-7540 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016027540 1156028140

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101602-7540 1016027540

ISUZU 1156028140 1156028140

Service parts 101602-7540 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8320

3. GOVERNOR 105419-1040

4. SUPPLY PUMP 105220-4561

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156635-3921

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4372

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:

101602-7540 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-1161 as _

104749-1162

Cross reference number

ZEXEL 101602-7540 1016027540

ISUZU 1156028140 1156028140

Zexel num

Bosch num

Firm num

Name

101602-7540
101602-8200

1156028140 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 * K

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 131424-4920

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 3.6 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 8.3

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 42.7 41.2 44.2

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.5+-0.5

Pump speed r/min 375 375 375

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)RACK CAP: R1 (3)Set idle sub-spring (4)Main spring setting
----------
K=8 R1=(17.5)mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the speed at aa, set the stopper bolt (2)Set the pump speed at bb. (3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=(17deg)+-5deg b=(5deg)+-5deg c=(4deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=2.5deg+-5deg b=46deg+-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=20deg
----------
a=(90deg)