101603-4270 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034270 1156019032


101603-4270 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-4270 1016034270
ISUZU 1156019032 1156019032

Cross reference number

ZEXEL 101603-4270 1016034270
ISUZU 1156019032 1156019032


Zexel num
Bosch num
Firm num
Name
101603-4270 
 
1156019032  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1 * 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 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   10.8
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   58.6 57 60.2
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   325 325 325
Average injection quantity mm3/st.   8.7 7.4 10
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(10.8)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   58.6 57.6 59.6
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(10.8)
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   60.2 58.6 61.8
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.1
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   60.4 58.8 62
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1+0.1
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   48.8 47.2 50.4
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   I
Rack position   R2
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   58.5 58.5 63.5
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   1300
Advance angle deg.   1.8 1.3 2.3
Timer adjustment_04
Pump speed r/min   1600
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-4270
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Torque control stroke: L1 (3)RACK LIMIT: RAL
----------
T1=A35 L1=(1)+-0.05mm RAL=R2mm
----------

Speed control lever angle

Test data 101603-4270
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=39deg+-5deg b=39deg+-3deg

Stop lever angle

Test data 101603-4270
N:Pump normal S:Stop the pump.
----------

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

0000001501 VARIABLE TORQUE CONTROL

Test data 101603-4270
N:Pump speed (r/min) R:Rack position (mm) Adjusting shim A Guide screw B (c) Nut (d) Nut (e) nut Torque control spring adjustment method for model responding to speed droop [Advice] Confirm that adjusting shim (A) thickness t = 1.3~1.5 mm is assembled before beginning adjustment. (1)Temporary idle lever position setting 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (2)Idling spring adjustment 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (3)Governor spring setting adjustment 1. Temporarily fix so that the governor shaft's guide screw B protrudes L2 (18 mm) from the end of the governor. 2. Set the control lever where it contacts the idle stopper bolt. 3. Increase the speed to Nh2+100 r/min or more. 4. Adjust using the two nuts C and D so that L1 = 0.3+0.5 mm and fix temporarily. 5. Adjust the protrusion L2 of the guide screw (B) so that the rack position at Nh1 is Rh1 and at Nh2 is Rh2. Then fix using the nut (E). 6. Further increase the speed and readjust the two nuts (C) and (D) so that there is no change in L1 until Nf+50 r/min. Then fix temporarily. [Advice] When L1 becomes smaller while speed is increasing to Nf+50 r/min, decrease speed by Nh2+100 r/min. Adjust so that L1 is even smaller, then again increase speed to Nf+50 r/min and confirm that L1 does not change. (4)Full load position setting 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (5)Torque control spring adjustment 1. Set the control lever so that it contacts the full speed stopper bolt. 2. At the specified speed Nf, adjust using the full speed stopper bolt so that governing begins, then fix temporarily. 3. Increase the speed and adjust using the two nuts (C) and (D) so that the rack position Rg can be obtained at the specified speed Ng. Fix temporarily. 4. Decrease the speed and confirm the governing point (the beginning of governing point) at the specified speed Nf. 5. Set the speed at Nf-50 r/min. 6. Measure the torque control stroke (L1) and adjust to the specified stroke (L1) using the shim (A). 7. After completing shim adjustment, repeat the above adjustment using the two nuts. 8. After confirming the specifications Nf and Ng, fix the two nuts (C) and (D). 9. In this condition, increase the speed and confirm that R = 0 can be obtained. (6)Full speed lever position setting 1. Set the control lever so that it contacts the full speed stopper bolt. 2. At the specified speed Nu, adjust using the full speed stopper bolt so that governing begins, then fix temporarily 3. Increase the speed and confirm that the specified rack position Ru can be obtained. 4. Adjust using the full speed stopper bolt so that governing begins at the specified speed Nf, then fix. 5. Confirm that the result is the same as that in '(5) Torque control spring adjustment.' 6. Confirm that the control lever operating angle is within the specifications. (7)Rack limit adjustment 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
----------

----------

0000001601 ACS

Test data 101603-4270
(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=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
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Ra=R1(10.8)mm Rb=- Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=58.6+-1cm3/1000st Q2=(46.8)+-1.6cm3/1000st

Timing setting

Test data 101603-4270
(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=14deg
----------
a=(60deg)




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