101602-4640 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016024640 1156021380

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-4640 1016024640

ISUZU 1156021380 1156021380

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Cross reference number

ZEXEL 101602-4640 1016024640

ISUZU 1156021380 1156021380

Zexel num

Bosch num

Firm num

Name

101602-4640
101602-4642

1156021380 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1MTC *

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 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 4.4 4.35 4.45

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 10.9

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 125.4 123.8 127

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 100 100

Boost pressure mmHg 750 750

Injection quantity adjustment_02

Adjusting point -

Rack position 6.1+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 9.2

Boost pressure kPa 12 10.7 13.3

Boost pressure mmHg 90 80 100

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 10.9

Boost pressure kPa 80 80 80

Boost pressure mmHg 600 600 600

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Set idle sub-spring (3)Main spring setting (4)Boost compensator stroke: BCL
----------
K=10 BCL=1.7+-0.1mm
----------

Speed control lever angle

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

----------
a=11deg+-5deg b=29deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)Use the hole above R = cc
----------
aa=0r/min bb=1-0.2mm cc=40mm
----------
a=32deg+-5deg b=(55deg)

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=15deg44min
----------
a=(100deg)

Information:

Balancer Unit - Front Mounted
Later units have needle roller bearings and all current balancer units have reversed weights.Front Dia. of Shafts (Driving and Driven) ... 1.2484/1.2490 in(31,71/31,73 mm)Inside Dia. of Front Balance Frame Bushes ... 1.2510/1.2526 in(31,78/31,82 mm)Running Clearance of Shafts in Bushes ... 0.002/0.0042 in(0,05/0,11 mm)Rear Dia. of Shafts (Driving and Driven) ... 0.9987/0.9992 in(25,37/25,38 mm)Inside Dia. of Rear Balance Frame Bushes ... 1.001/1.0022 in(25,43/25,46 mm)Running Clearance of Shafts in Bushes ... 0.0018/0.0035 in(0,05/0,09 mm)Shaft Dia. for Balance Weights ... 1.0622/1.0630 in(26,98/27,00 mm)Bore Dia. of Balance Weights ... 1.0625/1.0637 in(26,99/27,02 mm)Fit of Balance Weights on Shafts ... -0.0005/+0.0015 in(-0,01/+0,04 mm)Spigot Dia. of Earlier Balance Weights ... 2.499/2.500 in(63,47/63,50 mm)Recess Dia. in Earlier Balance Weights ... 2.500/2.501 in(63,50/63,53 mm)Spigot Dia. for Reversed Balance Weights ... 1.374/1.375 in(34,90/34,93 mm)Recess Dia. in Reversed Balance Weight Gears ... 1.375/1.376 in(34,93/34,95 mm)Fit of Gear on Balance Weight ... -0.000/+0.002 in(-0,00/+0,05 mm)Dia. of Earlier Shaft for Lub. Oil Pump Gear ... 0.4215/0.4235 in(10,71/10,76 mm)Bore Dia. of Earlier Lub. Oil Pump Drive Gear ... 0.425/0.426 in(10,79/10,82 mm)Clearance Fit of Earlier Gear on Shaft ... 0.0015/0.0045 in(0,04/0,11 mm)Dia. of Shaft for Later Lub. Oil Pump Gear ... 0.6500/0.6508 in(16,51/16,53 mm)Bore Dia. of Later Lub. Oil Pump Drive Gear ... 0.6513/0.6533 in(16,54/16,59 mm)Clearance Fit of Later Gear on Shaft ... 0.0005/0.0033 in(0,01/0,08 mm)Depth of Earlier Lub. Oil Pump Body ... 0.999/1.002 in(25,38/25,45 mm)Depth of Later Lub. Oil Pump Body ... 1.002/1.005 in(25,45/25,53 mm)Width of Lub. Oil Pump Drive Gears ... 0.998/1.000 in(25,35/25,40 mm)End Float of Earlier Oil Pump Gears (with joint) ... 0.003/0.008 in(0,08/0,20 mm)End Float of Later Oil Pump Gears ... 0.002/0.007 in(0,05/0,18 mm)Shaft Dia. for Lub. Oil Pump Driven Gear ... 0.4382/0.4386 in(11,13/11,14 mm)Bore Dia. of Lub. Oil Pump Driven Gear ... 0.4394/0.4404 in(11,16/11,19 mm)Running Clearance of Oil Pump Driven Gear ... 0.0008/0.0022 in(0,02/0,06 mm)Hub Dia. for Idler Gear ... 1.4984/1.4990 in(38,06/38,08 mm)Bore Dia. of Idler Gear Bush ... 1.500/1.5016 in(38,10/38,14 mm)Running Clearance of Idler Gear on Hub ... 0.001/0.0032 in(0,03/0,08 mm)Idler Gear End Float ... 0.008/0.014 in(0,20/0,36 mm)Balancer Unit - Centre Mounted
No. of Teeth on Driveshaft Gear ... 21Dia. of Driveshaft (at Front Bearing) ... 1.124/1.125 in(28,562/28,575 mm)Dia. of Driveshaft (at Rear Bearing) ... 0.936/0.937 in(23,787/23,800 mm)Dia. of Oil Pump Drive Splines ... 1.124/1.125 in(28,562/28,575 mm)No. of Splines ... 6Dia. of Balance Weight Drive Gear Splines ... 0.650/0.651 in(15,51/15,53 mm)No. of Splines ... 6Dia. of Front Bearing Bore (Driveshaft) ... 1.374/1.375 in(34,912/34,937 mm)Outside Dia. of Front Bearing (Driveshaft) ... 1.3748 in(34,92 mm)Inside Dia. of Front Bearing (Driveshaft) ... 1.125 in(28,58 mm)Dia. of Rear Bearing Bore (Driveshaft) ... 1.800/1.805 in(29,972/29,993 mm)Outside Dia. of Rear Bearing (Driveshaft) ... 1.181 in(30,00 mm)Inside Dia. of Rear Bearing (Driveshaft) ... 0.937 in(23,8 mm)Dia. of Balance Frame and End Frame Bush Bores ... 1.656/1.657 in(42,070/42,095 mm)Outside Dia. of Balance Frame and End Frame Bushes ... 1.66 in(42,164 mm)Inside Dia. of Balance Frame and End Frame Bushes ... 1.501/1.503 in(38,133/38,174 mm)Clearance of Balance Weight Shafts in Bushes ... 0.0025/0.0047 in(0,064/0,120 mm)Shaft Dia. of Balance Weights ... 1.498/1.499 in(38,054/38,069 mm)No. of