101603-4480 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034480 1156022660

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-4480 1016034480

ISUZU 1156022660 1156022660

Cross reference number

ZEXEL 101603-4480 1016034480

ISUZU 1156022660 1156022660

Zexel num

Bosch num

Firm num

Name

101603-4480

1156022660 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1TC * 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)
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 14

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 98.2 96.6 99.8

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 275 275 275

Average injection quantity mm3/st. 8 6.7 9.3

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(14)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 98.2 97.2 99.2

Basic *

Fixing the lever *

Boost pressure kPa 20 20

Boost pressure mmHg 150 150

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.7

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 90.5 87.3 93.7

Fixing the lever *

Boost pressure kPa 20 20

Boost pressure mmHg 150 150

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.3

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 85.4 82.2 88.6

Fixing the lever *

Boost pressure kPa 20 20

Boost pressure mmHg 150 150

Injection quantity adjustment_06

Adjusting point D

Rack position R1-1.65

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 49.3 46.1 52.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 90 90 98

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position (R1-0.3) -1.35

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position (R1-0.3) -0.85

Boost pressure kPa 4.7 4.7 7.4

Boost pressure mmHg 35 35 55

Boost compensator adjustment_03

Pump speed r/min 550 550 550

Rack position R1-0.3

Remarks
Measure actual boost pressure.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=C49 BCL=1.35+-0.1mm
----------

Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N3=800r/min C3=(6.4)deg t1=2--sec. t2=2--sec.
----------
N1=1200++r/min N2=1500r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=1.5--deg C2=6.4+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
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aa=35mm
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a=43deg+-5deg b=40deg+-3deg

Stop lever angle

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

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

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack limit adjustment (1)Fix the rack at the rack limit position Ra. (2)Install the shim (D) to the rod (C) and tighten nut (E). (3)Select a shim (D) so that the distance between the end surface of the pump and the nut (E) is L. (4)Release the rack fixing and mount the joint (B) and fix. (5)At this time, confirm that the shim (D) does not interfere with the joint (B). 2. Rack sensor adjustment (-0420) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set the speed to N1 r/min. (4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR. (6)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
L=33-0.2 mm N1=850r/min Ra=R1(14)mm
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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)