101603-0502 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030502 1156018012

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-0502 1016030502

ISUZU 1156018012 1156018012

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Buy INJECTION-PUMP ASSEMBLY 101603-0502 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-0502 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3261

3. GOVERNOR 105921-1063

4. SUPPLY PUMP 105210-4770

5. AUTOM. ADVANCE MECHANIS 105643-0190

6. COUPLING PLATE 105662-1051

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6941

11. Nozzle and Holder 1-15300-168-1

12. Open Pre:MPa(Kqf/cm2) 22.1{225}

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105015-6410

15. NOZZLE SET

Include in #1:

101603-0502 as INJECTION-PUMP ASSEMBLY

107692-1353 as _

Cross reference number

ZEXEL 101603-0502 1016030502

ISUZU 1156018012 1156018012

Zexel num

Bosch num

Firm num

Name

101603-0502
101603-0503

1156018012 ISUZU

INJECTION-PUMP ASSEMBLY
6SA1 *

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.7 3.65 3.75

Beginning of injection position
Governor 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 -

Rack position 11.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 78.5 76.9 80.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 260 260 260

Average injection quantity mm3/st. 10.7 8.7 12.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 78.5 77.5 79.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.05

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 76 72.8 79.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position R2(14.1)

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 96.5 96.5 106.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1250

Advance angle deg. 3.1 2.6 3.6

Timer adjustment_04

Pump speed r/min 1350

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B52
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18deg+-5deg b=(34deg)+-3deg

Stop lever angle

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

----------
a=25deg+-5deg b=40deg+-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=(40deg)

Information:

B. Back out (loosen) the lift adjustment screw 3/4 1/8of a turn.C. Put the nozzle in a vise with 8S2250 Holding Tool (1). Hold pressure adjusting screw (4) and tighten the locknut to a torque of 8.0-8.5 N m (70-75 lb in) using the 2P5487 Adapter (A). Recheck the opening pressure.Adjustment of 9L7883 Nozzles
1. Remove the nozzle from the tester and place in a vise using 8S2250 Nozzle Holding Tool (1). Loosen lift adjusting screw locknut (2). Loosen lift adjusting screw (3) two full turns counterclockwise.
If lift adjusting screw (3) is not loosened, the valve can be damaged in later steps.
2. Loosen pressure adjusting screw (4) and remove the nozzle from the nozzle holding tool. 3. Tilt the nozzle slightly down from the vertical position and remove pressure screw (4) and shims (5). If the shims do not come out of the nozzle, invert the nozzle and let the shims, spring and spring seat fall into the hand. If the valve comes out of its own weight, handle it carefully by its stem.4. To increase the opening pressure, add a 4N5730 Shim. The 4N5730 Shim is 0.13 mm (.005") thick and will increase the opening pressure approximately 1725 kPa (250 psi). A maximum of two shims can be added; if two shims do not increase opening pressure to specification given, discard the nozzle. 5. Assemble the nozzle, making sure the thickest shim (C) is against pressure screw (4). Put the nozzle in a vise using 8S2250 Nozzle Holding Tool (1). Tighten the pressure adjusting screw to 8.0-9.1 N m (70-80 lb in) torque.6. Remove the nozzle from the holding tool. Connect the nozzle, with the tip facing downward, to the tester. Point the nozzle tip into the 8S2270 Fuel Collector and the FT1384 Extension. Check the opening pressure and if it is not within specifications, repeat steps 4 and 5.Valve Lift Adjustment-9L7883 Nozzles
A. When the correct opening pressure is set, and while pumping test fluid through the nozzle, hold the lift adjusting screw locknut and slowly turn the lift adjusting screw clockwise (CW) until valve pressure rises 1380-3450 kPa (200-500 psi) above the nozzle opening pressure. Some test fluid may collect on the tip, but it must not flow at a rapid dribble.
Do not bend the valve by bottoming with too much force.
B. Back out the lift screw 3/4 1/8 turn, hold the lift adjusting screw, and tighten the locknut just enough so the screw will not turn; the lift is now set. C. Put the nozzle in a vise using 8S2250 Holding Tool (1). Tighten the locknut to 4.0-4.5 N m (35-40 lb in). Recheck valve opening pressure.Adjustment of 9L6969, 7N0449, 9N3299, 9N3700, 9N3979, 1W5829, 4W1819, 4W8483 and 7W3710 Nozzles
1. Put the nozzle in a vise using the 8S2250 Holding Tool (1). Loosen lift adjusting screw locknut (2). Turn lift adjusting screw (3) two full turns counterclockwise (CCW). 2. Hold lift adjusting screw (3) with a .08 mm (5/64") hex wrench (4) and