101603-0290 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030290 1156017761


101603-0290 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-0290 1016030290
ISUZU 1156017761 1156017761

Cross reference number

ZEXEL 101603-0290 1016030290
ISUZU 1156017761 1156017761


Zexel num
Bosch num
Firm num
Name
101603-0290 
101603-0295 
 
1156017761  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-TC *

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   13.8
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   89.9 88.3 91.5
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   -
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(13.8)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   89.9 88.9 90.9
Basic   *
Fixing the lever   *
Boost pressure kPa   20 20
Boost pressure mmHg   150 150
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.45
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   89.2 86 92.4
Fixing the lever   *
Boost pressure kPa   20 20
Boost pressure mmHg   150 150
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.1
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   83.8 80.6 87
Fixing the lever   *
Boost pressure kPa   20 20
Boost pressure mmHg   150 150
Injection quantity adjustment_06
Adjusting point   D
Rack position   12.6
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   54.5 52.9 56.1
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_07
Adjusting point   I
Rack position   15+-0.5
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   92 92 100
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   550 550 550
Rack position   12.6
Boost pressure kPa   2 2 4.7
Boost pressure mmHg   15 15 35
Boost compensator adjustment_02
Pump speed r/min   550 550 550
Rack position   13.1
Boost pressure kPa   4.7 4.7 7.4
Boost pressure mmHg   35 35 55
Boost compensator adjustment_03
Pump speed r/min   550 550 550
Rack position   R1-0.1
Remarks
Measure actual boost pressure.
 

Test data Ex:

Governor adjustment

Test data 101603-0290
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B04 BCL=(1.1)+-0.1mm
----------

Timer adjustment

Test data 101603-0290
(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N3=800r/min C3=(6.4)deg t1=2--sec. t2=2--sec.
----------
N1=1200++r/min N2=1500r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=1.5--deg C2=6.4+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

Test data 101603-0290
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=43deg+-5deg b=41deg+-3deg

Stop lever angle

Test data 101603-0290
N:Pump normal S:Stop the pump.
----------

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

0000001501 RACK SENSOR

Test data 101603-0290
(g) rack limit (h) Standard point (i) pump end face (j) Apply red paint. Rack sensor adjustment (154610-0420) 1. Rack limit adjustment (1)Fix the rack at the rack limit position Rl. (2)Attach shim (D) [shim thickness standard (17.5 - R1] to rod (C) and tighten nut (E). (3)Measure the distance X between the end face of the pump and the nut (E), and select a shim (D) so that X = 33-0.2mm. (4)Release the rack, mount the joint (B) and fix. (5)At this time, confirm that the shim (D) does not interfere with the joint (B). 2. Rack limit adjustment (amp-equipped type) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side and set the pump speed at No r/min. (3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join.
----------
N=- R=R1(13.8)mm VR=2+-0.01V
----------

Timing setting

Test data 101603-0290
(1)Pump vertical direction (2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)




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Group cross 101603-0290 ZEXEL

Isuzu 

101603-0290  

101603-0295 
 
1156017761 
INJECTION-PUMP ASSEMBLY
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1156017764 
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1156017765 
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