101602-7840 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016027840 1156029810

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-7840 1016027840

ISUZU 1156029810 1156029810

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Buy INJECTION-PUMP ASSEMBLY 101602-7840 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-7840 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8920

3. GOVERNOR 105411-1770

4. SUPPLY PUMP 105220-6240

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-0320

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4170

11. Nozzle and Holder 1-15300-331-0

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105025-0290

15. NOZZLE SET

Include in #1:

101492-0354 as _

101602-7840 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101602-7840 1016027840

ISUZU 1156029810 1156029810

Zexel num

Bosch num

Firm num

Name

101602-7840
101602-7841

1156029810 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-TQJ * 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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 8.1

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 100.5 99 102

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 65.3 65.3

Boost pressure mmHg 490 490

Injection quantity adjustment_02

Adjusting point C

Rack position 5.2+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 11.5 10.2 12.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 90 100

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-0.8

Boost pressure kPa 20 17.3 22.7

Boost pressure mmHg 150 130 170

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(8.1)

Boost pressure kPa 52 52 52

Boost pressure mmHg 390 390 390

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting
----------
K=12 BCL=0.8+-0.1mm
----------

Speed control lever angle

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

----------
a=8deg+-5deg b=24deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
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=12deg
----------
a=(100deg)

Information:

Water Pump
Inspection of Water Pump
If the inspection of the impeller and shaft finds abnormal noise or rough rotation, replace the assembly.
Inspection of impeller and shaft rotation conditionThermostat
Disassembly of Thermostat
Inspection of Thermostat
To test the thermostat operation, immerse the thermostat in a container filled with water, and heat the water while measuring the water temperature. Record the temperature at which the valve starts to open and the temperature at which the valve lift becomes 8 mm [0.3 in.] or more. (a) Stir the water in the container to ensure uniform temperature distribution.(b) When installing the thermostat, be sure to check the valve opening temperature indication stamped on the upper face of the thermostat mounting flange.
Inspection of thermostatOverheat Warning Unit (Thermo Switch)
Inspection of Overheat Warning Unit
Immerse the temperature sensor in oil, and measure the resistance while increasing the oil temperature. If the temperature measurement exceeds the standard value significantly, replace the thermo switch.
Since the inspection requires heating of oil to high temperatures, be careful not to get burns or start a fire.
Overheat warning unit