101603-0051 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030051 1156014973

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-0051 1016030051

ISUZU 1156014973 1156014973

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Cross reference number

ZEXEL 101603-0051 1016030051

ISUZU 1156014973 1156014973

Zexel num

Bosch num

Firm num

Name

101603-0051

1156014973 ISUZU

INJECTION-PUMP ASSEMBLY
6BB1 * 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 2.4 2.35 2.45

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 9.3

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 51.2 49.7 52.7

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

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.

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 51 51

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1200

Advance angle deg. 0.9 0.4 1.4

Timer adjustment_04

Pump speed r/min 1450

Advance angle deg. 2.1 1.6 2.6

Timer adjustment_05

Pump speed r/min 1650

Advance angle deg. 3 2.5 3.5

Timer adjustment_06

Pump speed r/min -

Advance angle deg. 5 5 5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)Excess fuel setting for starting: SXL
----------
DL=5.2-0.2mm SXL=9.5+0.2mm
----------

0000000901

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

----------
a=27deg+-3deg b=33deg+-5deg

Stop lever angle

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

----------
a=35.5deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(60deg)

Information:

start by: a) remove fuel injection pump housing and governor 1. Install the fuel injection pump housing on tool (A). 2. Remove the bolt (1) from the cover. Turn the injection pump camshaft until the timing pin (B) can be installed in the camshaft.3. Install tool (C) in the threads of the sleeve (3). Tighten the bolt until the sleeve can be removed.4. Remove the four bolts (4) that hold the body to the housing.5. Remove the body (2) from the housing. 6. Remove the idler gear (5) from the body.7. Remove the O-ring seal (6) from the body. Remove the two lip type seals (7) from the body. 8. Remove the drive gear (9) from the shaft.9. Remove the key (8) from the shaft.Install Fuel Transfer Pump
1. Install the key (1) and the drive gear (2) on the shaft.2. Put 5S1454 Sealing Compound on the outside diameter of the seals. 3. Install the inner seal in the body with the lip of the seal toward the inside with tooling (A).4. Install the outer seal in the body with the lip of the seal toward the outside with tooling (B).5. Remove the extra sealing compound from the body and the seals after installation. 6. Install the O-ring seal (4) and the idler gear (3) in the body. 7. Install the body (5) on the housing. 8. Install the four bolts (7) that hold the body to the housing.9. Put the timing pin (D) in position to keep the camshaft from turning.10. Put the sleeve (6) on the camshaft. 11. Tighten the sleeve into position on the shaft with 4B4280 Washer of tooling (C) approximately .25 in. (6.4 mm). Tighten the sleeve the remainder of the way with the 4N3371 Washer. The 4N3371 Washer is the washer which is on the tachometer drive bolt.
Do not hit the sleeve to install. Damage to governor will result.
12. The end play of the camshaft must be .023 .018 in. (0.58 0.46 mm) after sleeve (6) is installed.end by: a) install fuel injection pump housing and governor