101601-4590 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016014590 5156009551

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-4590 1016014590

ISUZU 5156009551 5156009551

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Cross reference number

ZEXEL 101601-4590 1016014590

ISUZU 5156009551 5156009551

Zexel num

Bosch num

Firm num

Name

101601-4590

5156009551 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 * 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)
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 11.1

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 66.8 65.3 68.3

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 325 325 325

Average injection quantity mm3/st. 9.3 8 10.6

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 R2(11.1+ -0.5)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 66.8 65.8 67.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position 11.2+-0. 5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 74 72.4 75.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position 11.05+-0 .5

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 71 69.4 72.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position 10.85+-0 .5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 48 46.4 49.6

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position 10.95+-0 .5

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 46.2 44.2 48.2

Fixing the lever *

Injection quantity adjustment_08

Adjusting point F

Rack position 11.25+-0 .5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 50 48 52

Fixing the lever *

Injection quantity adjustment_09

Adjusting point I

Rack position R3(13.6+ -0.5)

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 82 82 87

Fixing the rack *

Timer adjustment

Pump speed r/min 1350

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1400

Advance angle deg. 1.3

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 2.3 1.8 2.8

Timer adjustment_04

Pump speed r/min 1600

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Because the figures in brackets are the target values at torque cam adjustment, perform final adjustment in accordance with governor and injection quantity adjustment standards. (4)Perform governor spring adjustment by setting lever a. (5)After adjustment of the lever a setting, set the lever so that idle set point H can be obtained and confirm standard b. (6)After completing final adjustment, set the lever to obtain J. (7)Next, confirm rack position R1 or more is obtained when rotation is stopped. (8)In this condition, move the lever to the full position and confirm standard c. (excess fuel for starting operation limit). (9)After completing final adjustment, set speed at N1 using lever b. (10)In this condition, after operating the lever to the full position, confirm no excess fuel for starting (black smoke prevention limit). (11)For the excess fuel setting for starting rack position point I set the lever to obtain standard c in step (8) and then set the rack limit.
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T1=01 R1=12mm N1=225r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'b.'
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a=20deg+-5deg b=39deg+-3deg

Information:

4. Put rocker shaft assembly (3) in position on the cylinder head. 5. Install Jacobs washers (4) on the Jacobs stud assemblies (6). Put clean oil on the threads, and install washer and bolt (5) and Jacobs stud assemblies (6). Tighten the center bolt and Jacobs stud assemblies in increments of 70 N m (50 lb.ft.) each until a final torque of 450 N m (330 lb.ft.) is obtained.6. Make an adjustment to the valves to have a clearance of .015 (0.38 mm) for the intake valves and .030 (0.76 mm) for the exhaust valves. Tighten the locknuts to a torque of 28 4 N m (21 3 lb.ft.), and check the valve clearance again. See Testing And Adjusting for the correct procedure. 7. Install a new Jacobs O-ring seal (7) on the Jacobs oil supply adapter in the rocker shaft assembly. Put clean oil on the Jacobs O-ring seal.
Do not cause damage to the O-ring seals on the inner fuel lines.
8. Install inner fuel lines (8). Tighten the fuel line nuts to a torque of 40 7 N m (30 5 lb.ft.) with tooling (A) and (B). The Jacobs brake for the 3406B Truck Engine has only one support bracket (9).9. Put Jacobs support brackets (9) in position as shown. Put oil on the threads of Jacobs bolts (10). Install the washers on the Jacobs bolts. Install Jacobs bolts (10) that hold the Jacobs support bracket in place. Tighten the Jacobs bolts to a torque of 450 N m (330 lb.ft.). 10. Install Jacobs washers (11) on the Jacobs stud assemblies.
Be extra careful not