101602-0360 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016020360 5156010484

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-0360 1016020360

ISUZU 5156010484 5156010484

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Service parts 101602-0360 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-8230

3. GOVERNOR 105410-4141

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:

101602-0360 as INJECTION-PUMP ASSEMBLY

Include in #2:

104762-4010 as _

Cross reference number

ZEXEL 101602-0360 1016020360

ISUZU 5156010484 5156010484

Zexel num

Bosch num

Firm num

Name

101602-0360

5156010484 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 8.7

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 51.3 49.8 52.8

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.4

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 49.3 47.3 51.3

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 6.2+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Rack difference between N = N1 and N = N2
----------
K=14 N1=1175r/min N2=300r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=15deg+-5deg b=28deg+-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)

Information:

Illustration 1 g00564355
7W-2743 Electronic Speed Switch (ESS)
(1) Push button for Overspeed Verification
(2) Reset button
(3) Overspeed indicator lamp
(4) Seal screw plug for adjusting the engine overspeed
(5) Seal screw plug for adjusting the crank terminate speed
(6) Seal screw plug for adjusting the oil step pressure speed setting The oil step speed calibration increases the oil step speed setting or the oil step speed calibration decreases the oil step speed setting. Refer to the Speed Specification Chart in order to find the oil step speed that is equal to the engine rpm when the engine is running.
Remove the lockwire and the seal from seal screw plug (6). Remove seal screw plug (6) from the access hole for the oil step speed adjusting screw.
Use a small screwdriver to lightly turn the oil step speed adjusting screw in the direction of the "MAX" arrow or the clockwise direction. Turn the screw twenty times. The oil step speed adjusting screw will vary the setting of a potentiometer that is inside of the ESS. The oil step speed adjusting screw will not cause damage to the potentiometer. Also, the screw can not be removed if the screw is turned in the wrong direction.
Connect a voltmeter with the positive lead at terminal (ESS-13) and the negative lead at (ESS-5). Use a 6V-7070 Digital Multimeter or a voltmeter with the same accuracy. Measure the voltage.
For a specific engine rating, find the engine rpm in the column for the oil step speed setting in the Speed Specification Chart. Run the engine at the rpm that is specified in the table.
While the engine is running, look into the hole for the adjustment of the oil step speed. A red indicator lamp should be lighted. A positive voltage should be observed on the multimeter 9 seconds after the indicator lamp is lighted. Turn the oil step speed adjusting screw clockwise until the indicator lamp turns off. The oil step speed setting is above the present rpm of the engine. Slowly turn the oil step speed adjusting screw counterclockwise until the indicator lamp is lighted. After a 9 second delay, a positive voltage should be observed on the multimeter. This position is the correct setting for the oil step speed.
Install seal screw plug (6) in the access hole for the oil step speed adjusting screw. Tighten the screw to a torque of 0.20 0.03 N m (1.8 .3 lb in). Install the lockwire and the seal if the overspeed calibration and the crank terminate speed calibration are also complete.