101603-7451 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037451 1156026532

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-7451 1016037451

ISUZU 1156026532 1156026532

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Cross reference number

ZEXEL 101603-7451 1016037451

ISUZU 1156026532 1156026532

Zexel num

Bosch num

Firm num

Name

101603-7451
101603-7455

1156026532 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-TC1 *

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

Rack position
After adjusting injection quantity. R=A

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 13.3

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 98.6 97 100.2

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(13.3)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 98.6 97.6 99.6

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 98.6 95.4 101.8

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 55)

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 78.6 75.4 81.8

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_06

Adjusting point D

Rack position R2-1.35

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 54 50.8 57.2

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 93 93 125

Fixing the lever *

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position R2-1.35

Boost pressure kPa 3.3 3.3 6

Boost pressure mmHg 25 25 45

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R2(R1-0. 55)

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

Timer adjustment

Pump speed r/min (1170)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1325

Advance angle deg. 1.5 1 2

Timer adjustment_03

Pump speed r/min 1400

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)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke
----------
T1=F19
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=48mm
----------
a=43deg+-5deg b=(37deg)+-3deg

Stop lever angle

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

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

0000001501 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
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V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
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0000001601 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
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PL=131153-3720 ST=A716 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
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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=10deg
----------
a=(60deg)

Information:

(1) Torque for bushing ... 150 10 lb. ft.(20.7 1.4 mkg)(2) Thickness of spacers: 5M2697 Spacer ... .170 in.(4.32 mm)2M4208 Spacer ... .174 in.(4.42 mm)2M4209 Spacer ... .178 in.(4.52 mm)2M4210 Spacer ... .182 in.(4.62 mm)2M4211 Spacer ... .186 in.(4.72 mm)2M4212 Spacer ... .190 in.(4.82 mm)5M2691 Spacer ... .194 in.(4.93 mm)5S7189 Spacer ... .198 in.(5.03 mm)(3) 1S7590 Spring: Length under test force ... 1.522 in.(38.66 mm)Test force ... 22.6 1.1 lbs.(10.25 5 kg)Free length after test ... 1.751 in.(44.47 mm)Outside diameter ... .995 in.(25.27 mm)(4) Timing dimension for the fuel injection pumps: On engine with 8S7167 Gauge (A) ... 4.355 .002 in.(110.62 0.05 mm)Off engine with 8S7167 Gauge (A) ... 4.392 .002 in.(11.56 0.05 mm)(5) Length of pump plunger ... 2.7212 .0015 in.(69.118 0.038 mm) Minimum permissible length ... 2.7147 in.(68.953 mm)(6) Bore in the bearings for the rack: Bearing at the rear (later) ... .5020 .0015 in.(12.751 0.038 mm)Bearing at the front (later) ... .5023 .0015 in.(12.758 0.038 mm)Both bearings (earlier) ... .5010 .0003 in.(12.725 0.008 mm)Diameter of fuel rack ... .4983 to .4987 in.(12.656 to 12.666 mm)Maximum permissible clearance between rack and bearings ... .005 in.(0.13 mm)(7) Bore in bearings for the camshaft ... 2.1245 to 2.1255 in.(53.962 to 53.987 mm) Diameter of bearing journals of the camshaft ... 2.1215 to 2.1225 in.(53.886 to 53.911 mm)Maximum permissible clearance between the bearings and the camshaft journals ... .010 in.(0.25 mm) (8) Torque for the nuts that hold the fuel lines ... 30 5 lb. ft.(4.1 0.7 mkg)(9) Torque for the nuts that hold the nozzles ... 55 5 lb. ft.(7.6 0.7 mkg)(10) Body(11) Tighten nozzle finger tight in body.(12) Torque for glow plug ... 120 24 lb. in.(138.4 27.6 cm.kg)(13) Torque for precombustion chamber ... 150 10 lb. ft.(20.7 1.4 mkg)