101603-0783 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030783 1156018583

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-0783 1016030783

ISUZU 1156018583 1156018583

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Buy INJECTION-PUMP ASSEMBLY 101603-0783 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-0783 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4410

3. GOVERNOR 105931-3463

4. SUPPLY PUMP 105220-5220

5. AUTOM. ADVANCE MECHANIS 105644-0170

6. COUPLING PLATE 105661-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4823

11. Nozzle and Holder 1-15300-104-2

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101603-0783 as INJECTION-PUMP ASSEMBLY

101606-0022 as _

Cross reference number

ZEXEL 101603-0783 1016030783

ISUZU 1156018583 1156018583

Zexel num

Bosch num

Firm num

Name

101603-0783

1156018583 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 * K 14BF PE6AD PE

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 -

Rack position 11.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73.1 71.5 74.7

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 275 275 275

Average injection quantity mm3/st. 8 6.7 9.3

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(11.5)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73.1 72.1 74.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point I

Rack position 14+-0.5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 90 90 98

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1350--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=D27
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=42deg+-5deg b=35deg+-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=13deg
----------
a=(60deg)

Information:

(1) Bore in idler gear bearing ... 28.600 0.061 mm (1.1260 .0024 in) Diameter of idler gear shaft ... 28.512 0.013 mm (1.1225 .0005 in)Clearance between bearing and shaft ... .014 to .162 mm (.0011 to .0059 in)(2) Clearance between gear and body of pump ... 0.05 to 0.66 mm (.002 to .026 in)(3) Diameter of shafts for pump ... 22.217 0.005 mm (.8747 .0002 in) Bore in bearings for shafts ... 22.286 0.051 mm (.8774 .0020 in)Clearance between shafts and bearings ... .013 to .125 mm (.0010 to .0050 in)(4) Depth that bearings are installed in pump bodies ... 1.52 0.25 mm (.060 .010 in)(5) Length of gears ... 50.808 0.025 mm (2.0003 0.0010 in) Depth of bore in pump body for gears ... 50.935 0.020 mm (2.0053 0.0008 in)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in)(6) Length of gears ... 38.070 0.025 mm (1.4988 0.0010 in) Depth of bore in pump body for gears ... 38.197 0.020 mm (1.5038 0.0008 in)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in)(7) Distance from the end of the idler shafts to gear faces ... 21.03 0.13 mm (.828 .005 in) Maximum temperature of gear when shrinking in place ... 400°C (750°F)(8) Distance from the end of the drive shaft to gear face ... 38.23 0.13 mm (1.505 0.005 in) Maximum temperature of gear when shrinking in place ... 400°C (750°F)(9) Torque for bolt holding drive gear to drive shaft ... 47 9 N m (35 7 lb ft) Install the bearings in the cover and body for the oil pump so the bearing junctions (joints) are in the position shown.(10) Distance dowel extends from body ... 4.1 0.5 mm (.16 .02 in)(11) Shaft assembly. Distance shaft assembly extends from body ... 30.50 0.25 mm (1.201 0.010 in)
Section A-A
Oil Pump Bypass Spring(12) 115-7545 Spring: Length under test force ... 22.22 mm (.875 in)Test force ... 780 N (175 lb)Free length after test ... 25.4 mm (1.00 in)Outside diameter ... 18.54 mm (.730 in) Before running, lubricate pump with oil. Pump must rotate freely by hand.