101603-4470 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034470 1156021962

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-4470 1016034470

ISUZU 1156021962 1156021962

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Buy INJECTION-PUMP ASSEMBLY 101603-4470 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-4470 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2990

3. GOVERNOR 105472-1210

4. SUPPLY PUMP 105220-4561

5. AUTOM. ADVANCE MECHANIS 105612-3270

6. COUPLING PLATE 105661-0681

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4821

11. Nozzle and Holder 1-15300-104-0

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

13. NOZZLE-HOLDER 105031-3611

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101402-0792 as _

101603-4470 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-4470 1016034470

ISUZU 1156021962 1156021962

Zexel num

Bosch num

Firm num

Name

101603-4470
101603-4471

1156021962 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 * 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 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 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 8.7

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 49.9 48.4 51.4

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.7+-0.5

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 9.2 7.9 10.5

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 50 50

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 350--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 300

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min 1300

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Excess fuel setting for starting: SXL (4)Damper spring setting: DL (5)Rack difference between N = N1 and N = N2 (6)Tamper proof (shaft setting) (at N = N3).
----------
RT=1 TH=1.5mm SXL=9.1+0.2mm DL=6.2-0.2mm N1=1300r/min N2=900r/min N3=1300r/min
----------

0000000901

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

----------
a=21deg+-3deg b=33deg+-5deg

Stop lever angle

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

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

0000001501 TAMPER PROOF

N:Pump speed (r/min) R:Rack position (mm) 1. After governor adjustment, adjust the shaft as described below and stamp the cap. (1)Turn the load lever stopper bolt determining the full rack position (R = Rf) 1~2 turns counterclockwise. (2)Then, increase the full rack position. (3)Operate the pump at N = Nf and turn the shaft (B) clockwise. (4)Adjust so that full rack is Rf+0.4. (5)Tighten nut (A) to the specified torque. (6)Turn the stopper bolt clockwise the same amount that it was turned counter clockwise in (1). (7)Then, align with the full rack position (R = Rf) and fix. (8)Apply thread lock adhesive to the entire circumference of the cap (C) and tap it down to pressfit and seal it.. (9)Check for air tightness.
----------
Rf=8.1mm Nf=1300r/min
----------

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:

1 Remove the plug from the dash and install 3T306 Starting Aid Switch. Connect two purple wires, from the wiring harness, to the switch. 2 Put 3T157 Support Assembly (1) in position. Install two 6H1717 Bolts (2) as shown. On D6D Tractors with 4N6016 Refrigerant Compressor Group, remove the existing spacer so support (1) will fit at location (A); use the existing bolt. Remove the bolt and washer from the cylinder head and put 3T1417 Brace (3) in position. Install 2A4256 Spacer (4), S1591 Bolt (5) and 5M2894 Washer. Do not use spacer (4) on D6D Tractors. Install S1594 Bolt (6) and 5M2894 Washer. 3 Put 6N7674 Valve Assembly (7) in position on support assembly (1) and install two S1618 Bolts (8), 5P4116 Washers and 1D4716 Nuts. Put 7N2059 Clamp Assembly (9) in position on the support assembly and install two S1618 Bolts (8), 5P4116 Washers and 1D4716 Nuts. 4 Remove the plug from the manifold and install 6N9995 Atomizer Assembly (9). The orifices of the atomizer must be toward each end of the manifold. Install 5P7907 Connector (10) in valve assembly (7). Install one end of 9P3121 Tube (11) in atomizer assembly (9) and connect the other end of tube (11) to connector (10) with 5P6314 Sleeve (12) and 5P6313 Nut (13). Remove the plug from the bypass elbow and install 6N5899 Switch (14). Connect 9G3005 Wire Assembly (15) to switch (14) and to one wire from valve assembly (7). 5 Install 3D5102 Grommet and 2B2404 Clip (16) to hold tube (11). Connect 9G3006 Wire Assembly (17) to valve assembly (7) and to the purple wire, from the starting aid switch, at the rear of the engine. Use former clips (18) to hold wire assembly (17) in position.6 Remove cap (19) from valve assembly (7) and install 7N296 Cylinder Assembly.