101603-0160 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030160 1156015952


101603-0160 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-0160 1016030160
ISUZU 1156015952 1156015952

Cross reference number

ZEXEL 101603-0160 1016030160
ISUZU 1156015952 1156015952


Zexel num
Bosch num
Firm num
Name
101603-0160 
101603-0162 
 
1156015952  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1 *

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   10.9
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   60.3 58.7 61.9
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   325 325 325
Average injection quantity mm3/st.   8.7 7.4 10
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(10.9)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   60.3 59.3 61.3
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.1
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   65.2 63.6 66.8
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.   64 62.4 65.6
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1(10.9)
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   46.9 45.3 48.5
Fixing the lever   *
Timer adjustment
Pump speed r/min   1050--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1000
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1300
Advance angle deg.   1.8 1.3 2.3
Timer adjustment_04
Pump speed r/min   1600
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-0160
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL
----------
T1=19 RAL=13.6+0.2mm
----------

Speed control lever angle

Test data 101603-0160
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=45mm
----------
a=19.5deg+-5deg b=39deg+-3deg

Stop lever angle

Test data 101603-0160
N:Pump normal S:Stop the pump.
----------

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

0000001501 ACS

Test data 101603-0160
(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.9)mm Rb=- Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=60.3+-1cm3/1000st Q2=(47.6)+-1.6cm3/1000st

Timing setting

Test data 101603-0160
(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)




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