101603-0304 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030304 1156017945

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-0304 1016030304

ISUZU 1156017945 1156017945

Service parts 101603-0304 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2830

3. GOVERNOR 105931-2857

4. SUPPLY PUMP 105220-5220

5. AUTOM. ADVANCE MECHANIS 105644-0290

6. COUPLING PLATE 105661-0611

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5023

11. Nozzle and Holder 1-15300-106-2

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105015-4630

15. NOZZLE SET

Include in #1:

101603-0304 as INJECTION-PUMP ASSEMBLY

101603-8910 as _

Cross reference number

ZEXEL 101603-0304 1016030304

ISUZU 1156017945 1156017945

Zexel num

Bosch num

Firm num

Name

101603-0304
101603-0306

1156017945 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1TC *

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 14.1

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 101.2 99.6 102.8

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(14.1)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 101.2 100.2 102.2

Basic *

Fixing the lever *

Boost pressure kPa 20 20

Boost pressure mmHg 150 150

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.7

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 91.9 88.7 95.1

Fixing the lever *

Boost pressure kPa 20 20

Boost pressure mmHg 150 150

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.3

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 90.1 86.9 93.3

Fixing the lever *

Boost pressure kPa 20 20

Boost pressure mmHg 150 150

Injection quantity adjustment_06

Adjusting point D

Rack position R1-1.75

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 52.1 48.9 55.3

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 92 92 100

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position (R1-0.3) -0.45

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 (R1-0.3) -0.95

Boost pressure kPa 4.7 2 7.4

Boost pressure mmHg 35 35 55

Boost compensator adjustment_03

Pump speed r/min 550 550 550

Rack position R1-0.3

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

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B49 BCL=1.45+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=40deg+-3deg b=43deg+-5deg

Stop lever angle

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

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

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)