101603-0530 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030530 1156017751

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-0530 1016030530

ISUZU 1156017751 1156017751

Cross reference number

ZEXEL 101603-0530 1016030530

ISUZU 1156017751 1156017751

Zexel num

Bosch num

Firm num

Name

101603-0530

1156017751 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1TC * 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 3.6 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 R-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.

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=B04 BCL=(1.1)+-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=43deg+-5deg b=41deg+-3deg

Stop lever angle

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

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

0000001501 RACK SENSOR

V1:Output voltage Vf:Full side output voltage F:Full-speed I:Idle (a) Speed lever (B) Full side stopper bolt (c) Nut (d) Nut (e) nut (P) Potentiometer 1. Load sensor adjustment (1)Apply voltage V to between the potentiometer (P)'s connector terminals (1) ~ (3) and measure the output voltage between (1) ~ (2). (2)Move the speed lever (A) until it contacts the full side stopper bolt (B) and then turn the nut (D) to adjust the potentiometer (P)'s output voltage to Vf. (3)Confirm that the speed lever (A) turns smoothly between idle and Full side, then fix using nut (E). (Tightening torque: 4.4~7N.m{0.5~0.7kgf.m}) (4)Move the speed lever (A) several times to contact full side stopper bolt (B) and confirm that the potentiometer (P) output voltage is Vf. (5)Confirm that the speed lever (A) turns smoothly between idle and Full (b deg).
----------
V=DC24V Vf=16+-0.1V
----------

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)