101603-0930 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030930 1156018040

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-0930 1016030930

ISUZU 1156018040 1156018040

Cross reference number

ZEXEL 101603-0930 1016030930

ISUZU 1156018040 1156018040

Zexel num

Bosch num

Firm num

Name

101603-0930
101603-0931

1156018040 ISUZU

INJECTION-PUMP ASSEMBLY
6QA1 *

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 131424-0220

Overflow valve opening pressure kPa 147 113 181

Overflow valve opening pressure kgf/cm2 1.5 1.15 1.85

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 1-4-2-6- 3-5

Pre-stroke mm 3.7 3.65 3.75

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10.9

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 106.2 104.2 108.2

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 108.1 107.1 109.1

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.6+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11.5 9.2 13.8

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 150 150 150

Each cylinder's injection qty mm3/st. 140 140

Fixing the lever *

Remarks
After startup boost setting

Injection quantity adjustment_05

Adjusting point E

Rack position 9.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 73 71 75

Max. variation between cylinders % 0 -2 2

Fixing the lever *

Remarks
At absolute pressure 61.3 kPa {460 mmHg}

Timer adjustment

Pump speed r/min 500

Advance angle deg. 0.3

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 0.8 0.1 0.8

Timer adjustment_03

Pump speed r/min 700

Advance angle deg. 0.8 0.3 1.3

Timer adjustment_04

Pump speed r/min 900

Advance angle deg. 2 1.5 2.5

Timer adjustment_05

Pump speed r/min 1150

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)Excess fuel setting for starting: SXL (3)Aneroid compensator absolute pressure: P1 (4)Variable speed specification: idling adjustment (5)Main spring setting
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DL=6.5+-0.5mm SXL=12.1+-0.1mm P1=460+-5mmHg
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(14deg)+-5deg b=3deg+-5deg

0000000901

F:Full load I:Idle (1)Attach the return spring to the upper hole and adjust. (2)Stopper bolt setting
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a=21deg+-3deg b=30deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=65.5deg+-5deg b=71deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 1. Aneroid compensator unit adjustment (1)Screw in (A) to obtain L1. 2. Adjustment following governor installation (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.
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N1=700r/min L1=(0.1~0.5)mm
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R1=11.2mm R2=9.8mm P1=(90.6)kPa((680)mmHg) P2=61.3+-0.7kPa(460+-5mmHg) Q1=108.1+-1cm3/1000st Q2=(73)+-1cm3/1000st

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)-
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aa=17deg
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a=(60deg)