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

Information Cross number Calibration Data Calibration Data Ex

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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

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

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

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

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

0000001501 RACK SENSOR

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

(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)