Buy 101603-0300 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data


Information injection-pump assembly

ZEXEL 101603-0300 1016030300
ISUZU 1156017941 1156017941

You can buy parts: .

$119.35

11-05-2021
Steel Rule 3000x20x1,0 mm inox, satin, grad. inch-mm DIN2768m
Vogel Germany

Cross reference number

ZEXEL 101603-0300 1016030300
ISUZU 1156017941 1156017941


Zexel num Bosch num Firm num Firm Name
101603-0300 
101603-0306 
  1156017941  ISUZU INJECTION-PUMP ASSEMBLY
6BG1-TC *

Calibration Data:



Adjustment conditions
Test oil   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   R
Right


Injection timing adjustment
Direction of rotation (viewed from drive side)   R
Right
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.6 3.55 3.65
Beginning of injection position   NO.1
Drive side
Difference between angles 1 deg.   60 59.5 60.5
Cal 1-5
Difference between angles 2 deg.   120 119.5 120.5
Cal 1-3
Difference between angles 3 deg.   180 179.5 180.5
Cal 1-6
Difference between angles 4 deg.   240 239.5 240.5
Cyl.1-2
Difference between angles 5 deg.   300 299.5 300.5
Cal 1-4


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   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(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


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.


Timer adjustment
Pump speed r/min   1325--
Advance angle deg.   0 0 0
Remarks  
Start


Timer adjustment_02
Pump speed r/min   1275
Advance angle deg.   0.5


Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   1 0.5 1.5
Remarks  
Finish

Test data Ex:



Governor adjustment

Test data 101603-0300 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
----------



Speed control lever angle

Test data 101603-0300 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 101603-0300 N:Pump normal S:Stop the pump.
----------

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



Timing setting

Test data 101603-0300 (1)Pump vertical direction (2)Position of timer's threaded hole at the No. 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(60deg)





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Group cross 101603-0300 ZEXEL

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