101603-7760 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data


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:

101603-7760 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-7760 1016037760
ISUZU 1156027800 1156027800


Zexel num Bosch num Firm num Firm Name
101603-7760 
101603-7761 
  1156027800  ISUZU INJECTION-PUMP ASSEMBLY
6SA1 * K

Calibration Data:



Adjustment conditions
Test oil   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   L
Left


Injection timing adjustment
Direction of rotation (viewed from drive side)   L
Left
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.7 3.65 3.75
Beginning of injection position   NO.1
Governor side
Difference between angles 1 deg.   60 59.5 60.5
Cal 1-5
Difference between angles 2 deg.   120 119.5 120.5
Cal 1-3
Difference between angles 3 deg.   180 179.5 180.5
Cal 1-6
Difference between angles 4 deg.   240 239.5 240.5
Cyl.1-2
Difference between angles 5 deg.   300 299.5 300.5
Cal 1-4


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

Test data 101603-7760 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

Test data 101603-7760 F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

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



Stop lever angle

Test data 101603-7760 N:Pump normal S:Stop the pump.
----------

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



0000001501 TAMPER PROOF

Test data 101603-7760 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

Test data 101603-7760 (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)





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Group cross 101603-7760 ZEXEL

Isuzu 

101603-7700 
101603-7701 
  8943931740  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7701 
101603-7702 
  8943931742  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7702 
101603-7703 
  8943931743  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7703  9 400 615 207  8943931744  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7710 
101603-7711 
  8943930790  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7711  F 019 Z20 471  8943930791  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7711  F 019 Z20 471  8943930792  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7720 
101603-7721 
F 019 Z10 504  8943933421  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7721  9 400 615 208  8943933422  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7730  9 400 615 209  1156027761  INJECTION-PUMP ASSEMBLY
6SA1
101603-7740  9 400 615 210  1156027820  INJECTION-PUMP ASSEMBLY
6BD1-T
101603-7750 
101603-7751 
  1156027780  INJECTION-PUMP ASSEMBLY
6SD1
101603-7751  9 400 615 211  1156027781  INJECTION-PUMP ASSEMBLY
6SD1
101603-7760 
101603-7761 
  1156027800  INJECTION-PUMP ASSEMBLY
6SA1
101603-7761  9 400 615 212    INJECTION-PUMP ASSEMBLY
6SA1

Isuzu 

101603-7761  9 400 615 212  1156027801  INJECTION-PUMP ASSEMBLY
6SA1
101603-7770    1156027790  INJECTION-PUMP ASSEMBLY
6SA1
101603-7780 
101603-7781 
  8943935580  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7781 
101603-7782 
  8943935581  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7782  9 400 615 213  8943935582  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7790 
101603-7791 
  8943935590  INJECTION-PUMP ASSEMBLY
6HE1-N
101603-7791 
101603-7792 
  8943935591  INJECTION-PUMP ASSEMBLY
6HE1-N
101603-7792 
101603-7793 
  8943935592  INJECTION-PUMP ASSEMBLY
6HE1-N
101603-7793  9 400 615 214  8943935593  INJECTION-PUMP ASSEMBLY
6HE1-N
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