101602-4190 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016024190 1156016590

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-4190 1016024190

ISUZU 1156016590 1156016590

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Cross reference number

ZEXEL 101602-4190 1016024190

ISUZU 1156016590 1156016590

Zexel num

Bosch num

Firm num

Name

101602-4190
101602-4191

1156016590 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 *

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

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 9.8

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 64.7 63.7 65.7

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10+-0.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 59.8 57.8 61.8

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.5+-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 *

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
----------
K=14
----------

Speed control lever angle

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

----------
a=84deg+-5deg b=22deg+-5deg

Stop lever angle

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

----------
a=12deg+-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=22deg
----------
a=(90deg)

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Illustration 1 g06531932
Typical example
(1) 310-4948 Clip
(2) 310-4947 Clip
(3) 536-7106 Grommet
Illustration 2 g06533545
Typical view of DEF lines group in 794 AC/ 796 AC/ 798 AC machines
Table 1
Required Parts
Item Qty New Part Number Part Name Former Part Number(1)
1 12(2) 310-4948 Clip 3G-8054
2 12(2) 310-4947 Clip 3G-8057
3 12(2) 536-7106 Grommet 3G-8047
(1) The former part number listed is for reference only and may differ.
(2) 785G machines require only 8 quantity.New 310-4948 Clip (1) replaces the former 3G-8054 Clip in the DEF lines group/heater lines group.New 310-4947 Clip (2) replaces the former 3G-8057 Clip in the DEF lines group/heater lines group.New 536-7106 Grommet (3) replaces the former 3G-8047 Grommet in the DEF lines group/heater lines group.