101603-0800 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030800 1156018800


101603-0800 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-0800 1016030800
ISUZU 1156018800 1156018800

Cross reference number

ZEXEL 101603-0800 1016030800
ISUZU 1156018800 1156018800


Zexel num
Bosch num
Firm num
Name
101603-0800 
101603-0803 
 
1156018800  ISUZU
INJECTION-PUMP ASSEMBLY
6SA1 *

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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.7 3.65 3.75
Beginning of injection position
Governor 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   11.8
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   86.1 84.5 87.7
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.   11.9 9.9 13.9
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(11.8)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   86.1 85.1 87.1
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.2
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   77.6 74.4 80.8
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   R2(14)
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   104.5 104.5 114.5
Fixing the lever   *
Rack limit   *

Test data Ex:

Governor adjustment

Test data 101603-0800
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B34
----------

Timer adjustment

Test data 101603-0800
(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.
----------
L=1.5+-0.2mm N2=800r/min C2=(6.4deg) t1=2--sec. t2=2--sec.
----------
N1=1200++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=6.4+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

Test data 101603-0800
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18deg+-5deg b=32deg+-3deg

Stop lever angle

Test data 101603-0800
N:Pump normal S:Stop the pump.
----------

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

0000001501 RACK SENSOR

Test data 101603-0800
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack limit adjustment (1)Fix the rack at the rack limit position Ra. (2)Install the shim (D) to the rod (C) and tighten nut (E). (3)Select a shim (D) so that the distance between the end surface of the pump and the nut (E) is L. (4)Release the rack fixing and mount the joint (B) and fix. (5)At this time, confirm that the shim (D) does not interfere with the joint (B). 2. Rack sensor adjustment (-0420) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set the speed to N1 r/min. (4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR. (6)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
L=33-0.2mm N1=700r/min Ra=R1(11.8)mm
----------

Timing setting

Test data 101603-0800
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)




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Group cross 101603-0800 ZEXEL

Isuzu 

101603-0800  

101603-0803 
 
1156018800 
INJECTION-PUMP ASSEMBLY
6SA1
 
1156018801 
INJECTION-PUMP ASSEMBLY
6SA1
 
1156018802 
INJECTION-PUMP ASSEMBLY
6SA1
 
1156018803 
INJECTION-PUMP ASSEMBLY
6SA1
 
1156018411 
INJECTION-PUMP ASSEMBLY
6QA2
 
1156018421 
INJECTION-PUMP ASSEMBLY
6QA2
 
1156018422 
INJECTION-PUMP ASSEMBLY
6QA2
 
1156018710 
INJECTION-PUMP ASSEMBLY
6BD1T
 
1156018720 
INJECTION-PUMP ASSEMBLY
6BD1T
9 400 615 006 
1156018730 
INJECTION-PUMP ASSEMBLY
6BD1
 
1156018740 
INJECTION-PUMP ASSEMBLY
6BD1
 
1156015762 
INJECTION-PUMP ASSEMBLY
6BD1T
 
1156015764 
INJECTION-PUMP ASSEMBLY
6BD1-T
 
1156019820 
INJECTION-PUMP ASSEMBLY
6SA1
 
1156019821 
INJECTION-PUMP ASSEMBLY
6SA1
9 400 615 007 
1156019822 
INJECTION-PUMP ASSEMBLY
6SA1
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