101601-8122 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016018122 1156013404


101601-8122 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101601-8122 1016018122
ISUZU 1156013404 1156013404

Cross reference number

ZEXEL 101601-8122 1016018122
ISUZU 1156013404 1156013404


Zexel num
Bosch num
Firm num
Name
101601-8122 
101601-8125 
 
1156013404  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1-T *

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   132424-0620
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   3.4 3.35 3.45
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   10.9
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   77.4 76.4 78.4
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   9.7+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   9.4 8.1 10.7
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(10.9)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   77.4 76.4 78.4
Basic   *
Fixing the lever   *
Boost pressure kPa   16.7 16.7
Boost pressure mmHg   125 125
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.3
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   80.8 77.6 84
Fixing the lever   *
Boost pressure kPa   16.7 16.7
Boost pressure mmHg   125 125
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.4
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   53.7 50.5 56.9
Fixing the lever   *
Boost pressure kPa   16.7 16.7
Boost pressure mmHg   125 125
Injection quantity adjustment_06
Adjusting point   I
Rack position   13+-0.5
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   82 82 87
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   (R1-0.4) -0.5
Boost pressure kPa   2 2 4.7
Boost pressure mmHg   15 15 35
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   (R1-0.4) -0.3
Boost pressure kPa   4.7 4.7 7.4
Boost pressure mmHg   35 35 55
Boost compensator adjustment_03
Pump speed r/min   500 500 500
Rack position   R1-0.4
Remarks
Measure actual boost pressure.
 
Timer adjustment
Pump speed r/min   1300--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1250
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1350
Advance angle deg.   0.7 0.2 1.2
Timer adjustment_04
Pump speed r/min   1450
Advance angle deg.   1.5 1.2 1.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-8122
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=A44 BCL=0.5+-0.05mm
----------

Speed control lever angle

Test data 101601-8122
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=40deg+-5deg b=34deg+-3deg

Stop lever angle

Test data 101601-8122
N:Pump normal S:Stop the pump.
----------

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

0000001501 RACK SENSOR

Test data 101601-8122
V1:Output voltage Vf:Full side output voltage F:Full-speed I:Idle (a) Speed lever (B) Full side stopper bolt (c) Nut (d) Nut (e) nut (P) Potentiometer 1. Load sensor adjustment (1)Apply voltage V to between the potentiometer (P)'s connector terminals (1) ~ (3) and measure the output voltage between (1) ~ (2). (2)Move the speed lever (A) until it contacts the full side stopper bolt (B) and then turn the nut (D) to adjust the potentiometer (P)'s output voltage to Vf. (3)Confirm that the speed lever (A) turns smoothly between idle and Full side, then fix using nut (E). (Tightening torque: 4.4~7N.m{0.5~0.7kgf.m}) (4)Move the speed lever (A) several times to contact full side stopper bolt (B) and confirm that the potentiometer (P) output voltage is Vf. (5)Confirm that the speed lever (A) turns smoothly between idle and Full (b deg).
----------
V=DC24V Vf=16+-0.1V
----------

Timing setting

Test data 101601-8122
(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)




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Group cross 101601-8122 ZEXEL

Isuzu 

 
1156013401 
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1156013403 
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101601-8122  

101601-8125 
 
1156013404 
INJECTION-PUMP ASSEMBLY
6BD1-T
 
1156013406 
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1156013407 
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