101603-0452 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030452 1156017732

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-0452 1016030452

ISUZU 1156017732 1156017732

Cross reference number

ZEXEL 101603-0452 1016030452

ISUZU 1156017732 1156017732

Zexel num

Bosch num

Firm num

Name

101603-0452
101603-0453

1156017732 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 *

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 134424-0620

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 12.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 76.8 75.2 78.4

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 260 260 260

Average injection quantity mm3/st. 8.1 6.8 9.4

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(12.6)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 76.8 75.8 77.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point I

Rack position 15.3+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 92 92 100

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
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T1=C32
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Timer adjustment

(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.
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L=1.5+-0.2mm N3=800r/min C3=(6.4deg) t1=2--sec. t2=2--sec.
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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

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
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aa=35mm
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a=42deg+-5deg b=(43deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=25deg+-5deg b=40deg+-5deg

0000001501 RACK SENSOR

(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.
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N=1000r/min R=R1(12.6)mm VR=2+-0.01V
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