101603-0080 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030080 1156015012

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-0080 1016030080

ISUZU 1156015012 1156015012

Service parts 101603-0080 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-0570

3. GOVERNOR 105931-3170

4. SUPPLY PUMP 105220-4781

5. AUTOM. ADVANCE MECHANIS 105612-3070

6. COUPLING PLATE 105661-0661

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101603-0080 as INJECTION-PUMP ASSEMBLY

101606-0003 as _

Cross reference number

ZEXEL 101603-0080 1016030080

ISUZU 1156015012 1156015012

Zexel num

Bosch num

Firm num

Name

101603-0080

1156015012 ISUZU

INJECTION-PUMP ASSEMBLY
6BB1 * 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 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 3.6 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 -

Rack position 10.8

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 61.4 59.8 63

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. 7.4 6.1 8.7

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(10.8)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 61.4 60.4 62.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 71 69.4 72.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.05

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 66 64.4 67.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 45.7 44.1 47.3

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position 13.6+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 87 87 95

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1400--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1350

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 1.3

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 2.3 1.8 2.8

Timer adjustment_05

Pump speed r/min 1600

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Torque control stroke: L2 (3)RACK LIMIT (4)Perform speed droop adjustment using the torque control spring in accordance with specification 'a' and confirm specification 'b.' Set the final full speed position lever in accordance with specification 'a.'
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T1=27 L2=(1.1)+-0.05mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=42deg+-5deg b=37deg+-3deg

Stop lever angle

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

0000001501 VARIABLE TORQUE CONTROL

N:Pump speed (r/min) R:Rack position (mm) Adjusting shim A Guide screw B (c) Nut (d) Nut (e) nut Torque control spring adjustment method for model responding to speed droop [Advice] Confirm that adjusting shim (A) thickness t = 1.3~1.5 mm is assembled before beginning adjustment. (1)Temporary idle lever position setting 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (2)Idling spring adjustment 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (3)Governor spring setting adjustment 1. Temporarily fix so that the governor shaft's guide screw B protrudes L2 (18 mm) from the end of the governor. 2. Set the control lever where it contacts the idle stopper bolt. 3. Increase the speed to Nh2+100 r/min or more. 4. Adjust using the two nuts C and D so that L1 = 0.3+0.5 mm and fix temporarily. 5. Adjust the protrusion L2 of the guide screw (B) so that the rack position at Nh1 is Rh1 and at Nh2 is Rh2. Then fix using the nut (E). 6. Further increase the speed and readjust the two nuts (C) and (D) so that there is no change in L1 until Nf+50 r/min. Then fix temporarily. [Advice] When L1 becomes smaller while speed is increasing to Nf+50 r/min, decrease speed by Nh2+100 r/min. Adjust so that L1 is even smaller, then again increase speed to Nf+50 r/min and confirm that L1 does not change. (4)Full load position setting 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (5)Torque control spring adjustment 1. Set the control lever so that it contacts the full speed stopper bolt. 2. At the specified speed Nf, adjust using the full speed stopper bolt so that governing begins, then fix temporarily. 3. Increase the speed and adjust using the two nuts (C) and (D) so that the rack position Rg can be obtained at the specified speed Ng. Fix temporarily. 4. Decrease the speed and confirm the governing point (the beginning of governing point) at the specified speed Nf. 5. Set the speed at Nf-50 r/min. 6. Measure the torque control stroke (L1) and adjust to the specified stroke (L1) using the shim (A). 7. After completing shim adjustment, repeat the above adjustment using the two nuts. 8. After confirming the specifications Nf and Ng, fix the two nuts (C) and (D). 9. In this condition, increase the speed and confirm that R = 0 can be obtained. (6)Full speed lever position setting 1. Set the control lever so that it contacts the full speed stopper bolt. 2. At the specified speed Nu, adjust using the full speed stopper bolt so that governing begins, then fix temporarily 3. Increase the speed and confirm that the specified rack position Ru can be obtained. 4. Adjust using the full speed stopper bolt so that governing begins at the specified speed Nf, then fix. 5. Confirm that the result is the same as that in '(5) Torque control spring adjustment.' 6. Confirm that the control lever operating angle is within the specifications. (7)Rack limit adjustment 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
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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)-
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aa=14deg
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a=(60deg)