101603-4171 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034171 1156021301

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-4171 1016034171

ISUZU 1156021301 1156021301

Cross reference number

ZEXEL 101603-4171 1016034171

ISUZU 1156021301 1156021301

Zexel num

Bosch num

Firm num

Name

101603-4171
101603-4173

1156021301 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 *

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)
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 3.6 3.55 3.65

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 12.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 76.8 75.2 78.4

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. 8.1 6.8 9.4

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 1000 1000 1000

Average injection quantity mm3/st. 76.8 75.8 77.8

Fixing the lever *

Injection quantity adjustment_04

Adjusting point I

Rack position 15.3+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 92 92 100

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1350--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Air cylinder operating pressure: P1 or more (4)Air cylinder operating pressure: P2
----------
T1=C32 P1=3kg/cm2 P2=0kg/cm2
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)When air cylinder OFF. (3)Air cylinder operating pressure: at bb (4)Stopper bolt set position 'H'
----------
aa=35mm bb=3kg/cm2
----------
a=(35deg)+-3deg b=(43deg)+-3deg c=42deg+-5deg

Stop lever angle

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

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

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=13deg
----------
a=(60deg)