101603-0420 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030420 1156017620


101603-0420 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-0420 1016030420
ISUZU 1156017620 1156017620

Cross reference number

ZEXEL 101603-0420 1016030420
ISUZU 1156017620 1156017620


Zexel num
Bosch num
Firm num
Name
101603-0420 
 
1156017620  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1-T * 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   3.4 3.35 3.45
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   900 900 900
Average injection quantity mm3/st.   77.4 75.8 79
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(10.9)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   77.4 76.4 78.4
Basic   *
Fixing the lever   *
Boost pressure kPa   16.7 16.7
Boost pressure mmHg   125 125
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.3
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   80.8 77.6 84
Fixing the lever   *
Boost pressure kPa   16.7 16.7
Boost pressure mmHg   125 125
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.4
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   53.7 50.5 56.9
Fixing the lever   *
Boost pressure kPa   16.7 16.7
Boost pressure mmHg   125 125
Injection quantity adjustment_06
Adjusting point   I
Rack position   13+-0.5
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   82 82 87
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   (R1-0.4) -0.5
Boost pressure kPa   2 2 4.7
Boost pressure mmHg   15 15 35
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   (R1-0.4) -0.3
Boost pressure kPa   4.7 4.7 7.4
Boost pressure mmHg   35 35 55
Boost compensator adjustment_03
Pump speed r/min   500 500 500
Rack position   R1-0.4
Remarks
Measure actual boost pressure.
 
Timer adjustment
Pump speed r/min   1300--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1250
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1350
Advance angle deg.   0.7 0.2 1.2
Timer adjustment_04
Pump speed r/min   1450
Advance angle deg.   1.5 1.2 1.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-0420
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=A44 BCL=0.5+-0.1mm
----------

Speed control lever angle

Test data 101603-0420
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=40deg+-5deg b=34deg+-3deg

Stop lever angle

Test data 101603-0420
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101603-0420
(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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