101603-4042 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034042 1156020482

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-4042 1016034042

ISUZU 1156020482 1156020482

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Cross reference number

ZEXEL 101603-4042 1016034042

ISUZU 1156020482 1156020482

Zexel num

Bosch num

Firm num

Name

101603-4042
101603-4043

1156020482 ISUZU

INJECTION-PUMP ASSEMBLY
6SA1T *

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 12.4

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 111.5 109.9 113.1

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 290 290 290

Average injection quantity mm3/st. 9.7 7.7 11.7

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(12.4)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 111.5 110.5 112.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.35

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 105.4 102.2 108.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 99.5 99.5 109.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1250

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
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T1=B62
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Speed control lever angle

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

----------
a=18deg+-5deg b=31deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=25deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
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N1=850r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
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Ra=R1(12.4)mm Rb=R1-0.4mm Pa=88+-2.7kPa(660+-20mmHg) Pb=65.3kPa(490mmHg) Q1=111.5+-1cm3/1000st Q2=(99)+-1.6cm3/1000st

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at the No. 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(40deg)

Information:

9. Remove bracket assembly (16) and link (17). 10. Put identification marks on fuel racks (18) and (19), and remove the fuel racks. 11. Put identification marks on each spacer (20) and lifter (21) so they can be installed in their original position. 12. Remove fuel injection pump camshaft (22) from the pump housing.13. Remove O-ring seal (23). 14. Inspect link pivot shaft (24) and bracket locating pin (25). Make a replacement by removal of shaft (24) and dowel (25) with Tool (D). 15. Inspect upper bearing (26) and the lower bearing that hold the pinion gear in the pump housing.16. Make a replacement of bearings (26) if necessary.17. Inspect idler gear shaft (27). If a replacement is necessary, remove the shaft with Tooling (D). 18. Inspect fuel rack bearings (28) and camshaft bearings (29). If a replacement is necessary, remove bearings (28) and (29).19. Use Tooling (E) to remove bearings (28). 20. Remove regulator valve (30). 21. Remove pin (31) to disassemble the regulator valve, and inspect the components.22. Piston (32) must move freely in valve body (30).23. Make a reference to the Specifications for spring (34).24. Make a replacement of O-ring seals (33).Assemble Fuel Injection Pump Housing
Pin (2) must not extend out of either side of valve body (3).
1. Install spring (4), piston (1) and pin (2) in valve body (3).2. Put clean engine oil on the valve body and O-ring seals (5). Install the oil bypass valve in the pump housing. Tighten the bypass valve body to a torque of 68 14 N m (50 10 lb ft). 3. Install the camshaft front and rear bearings with Tooling (A). Install the front bearing until it is a distance of 1.0 0.5 mm (.04 .02 in) from the front surface of the pump housing. Make sure both oil holes in bearing are in alignment with the oil holes in the pump housing. 4. Put Tool (B) in the fuel pump housing with the dowels of Tool (B) in alignment with the left fuel rack bore. Install the bolt that holds the tool in place on the housing.5. Put a new bearing in position with the tab of the bearing up. Install the bearing with Tool (C) until the shoulder of Tool (C) makes contact with Tool (B).6. Turn Tool (B), and make an alignment of the dowels on Tool (B) with the right fuel rack bore.7. Do Step 3 again for the left fuel rack bearing. 8. Install shaft (6) to a height of 16.8 0.5 mm (.66 .02 in). 9. Make sure the chamfer on the lower bearing for the pinion gear is toward the inside and the notch is in the location shown. Install the bearing 28.4 0.5 mm (1.12 .02 in) below the bearing bore surface with Tooling (D).10. Make sure the chamfer on the upper bearing for the pinion gear is toward the inside and the notch is in the location shown. Use