101603-4042 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data


Information injection-pump assembly

ZEXEL 101603-4042 1016034042
ISUZU 1156020482 1156020482

Cross reference number

ZEXEL 101603-4042 1016034042
ISUZU 1156020482 1156020482


Zexel num Bosch num Firm num Firm Name
101603-4042 
101603-4043 
  1156020482  ISUZU INJECTION-PUMP ASSEMBLY
6SA1T *

Calibration Data:



Adjustment conditions
Test oil   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   L
Left


Injection timing adjustment
Direction of rotation (viewed from drive side)   L
Left
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.7 3.65 3.75
Beginning of injection position   NO.1
Governor side
Difference between angles 1 deg.   60 59.5 60.5
Cal 1-5
Difference between angles 2 deg.   120 119.5 120.5
Cal 1-3
Difference between angles 3 deg.   180 179.5 180.5
Cal 1-6
Difference between angles 4 deg.   240 239.5 240.5
Cyl.1-2
Difference between angles 5 deg.   300 299.5 300.5
Cal 1-4


Injection quantity adjustment
Adjusting point   -
Rack position   12.4
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   111.5 109.9 113.1
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   290 290 290
Average injection quantity mm3/st.   9.7 7.7 11.7
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(12.4)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   111.5 110.5 112.5
Basic   *
Fixing the lever   *


Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.35
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   105.4 102.2 108.6
Fixing the lever   *


Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   99.5 99.5 109.5
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

Test data 101603-4042 N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B62
----------



Speed control lever angle

Test data 101603-4042 F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18deg+-5deg b=31deg+-3deg



Stop lever angle

Test data 101603-4042 N:Pump normal S:Stop the pump.
----------

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



0000001501 ACS

Test data 101603-4042 (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=(0.1~0.5)mm
----------
Ra=R1(12.4)mm Rb=R1-0.4mm Pa=88+-2.7kPa(660+-20mmHg) Pb=65.3kPa(490mmHg) Q1=111.5+-1cm3/1000st Q2=(99)+-1.6cm3/1000st



Timing setting

Test data 101603-4042 (1)Pump vertical direction (2)Position of timer's threaded hole at the No. 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(40deg)





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Group cross 101603-4042 ZEXEL

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