101603-0910 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030910 1156019600

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-0910 1016030910

ISUZU 1156019600 1156019600

Service parts 101603-0910 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3240

3. GOVERNOR 105921-1310

4. SUPPLY PUMP 105210-4770

5. AUTOM. ADVANCE MECHANIS 105643-0210

6. COUPLING PLATE 105662-0430

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6981

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105015-6630

15. NOZZLE SET

Include in #1:

101603-0910 as INJECTION-PUMP ASSEMBLY

107692-1403 as _

Cross reference number

ZEXEL 101603-0910 1016030910

ISUZU 1156019600 1156019600

Zexel num

Bosch num

Firm num

Name

101603-0910
101603-4040

1156019600 ISUZU

INJECTION-PUMP ASSEMBLY
6SA1T * 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)
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 12.6

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 116.3 114.7 117.9

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 280 280 280

Average injection quantity mm3/st. 9.4 7.4 11.4

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 850 850 850

Average injection quantity mm3/st. 116.3 114.7 117.9

Basic *

Fixing the lever *

Remarks
After setting aneroid compensatory.

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 112.8 109.6 116

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position R2(14.2)

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 102.5 102.5 112.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1250

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B40
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=19deg+-5deg b=28deg+-3deg

Stop lever angle

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

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

0000001501 ACS

(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 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)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=850r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=0.1~0.5mm
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Ra=R1(12.6)mm Rb=R3(12)mm Pa=4+-2.7kPa(30+-20mmHg) Pb=36kPa(270mmHg) Q1=116.3+-1mm3/st Q2=103.6+-1.6mm3/st

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=15deg
----------
a=(40deg)