101603-0840 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030840 1156018720


101603-0840 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-0840 1016030840
ISUZU 1156018720 1156018720

Service parts 101603-0840 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-2760
3. GOVERNOR 105931-3500
4. SUPPLY PUMP 105220-4781
5. AUTOM. ADVANCE MECHANIS 105612-3210
6. COUPLING PLATE 105661-0681
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6060
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 18.1(185)
13. NOZZLE-HOLDER 105031-3930
14. NOZZLE 105015-5730
15. NOZZLE SET

Include in #1:

101603-0840 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-0840 1016030840
ISUZU 1156018720 1156018720


Zexel num
Bosch num
Firm num
Name
101603-0840 
 
1156018720  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1T * K 14BE PE6A PE

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 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   11.6
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   72.7 71.1 74.3
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   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   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.6)
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   72.7 71.7 73.7
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(11.6)
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   81.1 77.9 84.3
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.15
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   56.7 53.5 59.9
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   13.3+-0. 5
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   79 79 84
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1050--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1000
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1150
Advance angle deg.   0.5 0.5 1.1
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-0840
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=A28
----------

Speed control lever angle

Test data 101603-0840
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=34deg+-5deg b=36deg+-3deg

Stop lever angle

Test data 101603-0840
N:Pump normal S:Stop the pump.
----------

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

0000001501 ACS

Test data 101603-0840
(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(11.6)mm Rb=R4(11.4)mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=72.7+-1cm3/1000st Q2=70.2+-1.6cm3/1000st

Timing setting

Test data 101603-0840
(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=16deg
----------
a=(60deg)




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Group cross 101603-0840 ZEXEL

Isuzu 

 
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
101603-0840  
 
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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