101603-7760 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037760 1156027800

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-7760 1016037760

ISUZU 1156027800 1156027800

Service parts 101603-7760 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3261

3. GOVERNOR 105921-5660

4. SUPPLY PUMP 105210-5100

5. AUTOM. ADVANCE MECHANIS 105643-0200

6. COUPLING PLATE 105662-1170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6941

11. Nozzle and Holder 1-15300-168-1

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105015-6410

15. NOZZLE SET

Include in #1:

101402-4143 as _

101603-7760 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-7760 1016037760

ISUZU 1156027800 1156027800

Zexel num

Bosch num

Firm num

Name

101603-7760
101603-7761

1156027800 ISUZU

INJECTION-PUMP ASSEMBLY
6SA1 * 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 132424-0620

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.7 3.65 3.75

Beginning of injection position
Governor 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 -

Rack position 11.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 78.5 76.9 80.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 260 260 260

Average injection quantity mm3/st. 10.7 8.7 12.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 78.5 77.5 79.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.05

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 76 72.8 79.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 96.5 96.5 106.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1350

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=B52
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18deg+-5deg b=(34deg)+-3deg

Stop lever angle

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

----------
a=25deg+-5deg b=40deg+-5deg

0000001501 TAMPER PROOF

1. Set the full load. (1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to R1. (2)Set using the screw (A) so that the rack position is as shown above and tighten the locknut. (3)Again set in the correct rack position using the load lever.
----------
R1=0.4mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(40deg)