101603-4530 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034530 1156022700

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-4530 1016034530

ISUZU 1156022700 1156022700

Cross reference number

ZEXEL 101603-4530 1016034530

ISUZU 1156022700 1156022700

Zexel num

Bosch num

Firm num

Name

101603-4530

1156022700 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1T * 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 3.4 3.35 3.45

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.25 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.25 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.25 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.25 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.25 300.25

Injection quantity adjustment

Adjusting point -

Rack position 11.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 78.5 76.9 80.1

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 -

Rack position 9.7+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.2)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 78.5 77.5 79.5

Fixing the lever *

Boost pressure kPa 15.3 15.3

Boost pressure mmHg 115 115

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.25

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 84.1 80.9 87.3

Fixing the lever *

Boost pressure kPa 15.3 15.3

Boost pressure mmHg 115 115

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.5

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 55.7 52.5 58.9

Fixing the lever *

Boost pressure kPa 15.3 15.3

Boost pressure mmHg 115 115

Injection quantity adjustment_06

Adjusting point I

Rack position 13+-0.5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 82 82 87

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position (R1-0.5) -0.8

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position (R1-0.5) -0.6

Boost pressure kPa 4.7 4.7 7.4

Boost pressure mmHg 35 35 55

Boost compensator adjustment_03

Pump speed r/min 600 600 600

Rack position R1-0.5

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
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T1=C15 BCL=0.8+-0.1mm
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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.
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L=1.5+-0.2mm N3=800r/min C3=(6.4deg) t1=2--sec. t2=2--sec.
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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=40deg+-5deg b=34deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=25deg+-5deg b=40deg+-5deg

0000001501 RACK SENSOR

(g) rack limit (h) Standard point (i) pump end face (j) Apply red paint. Rack sensor adjustment (154610-0420) 1. Rack limit adjustment (1)Fix the rack at the rack limit position Rl. (2)Attach shim (D) [shim thickness standard (17.5 - R1] to rod (C) and tighten nut (E). (3)Measure the distance X between the end face of the pump and the nut (E), and select a shim (D) so that X = 33-0.2mm. (4)Release the rack, mount the joint (B) and fix. (5)At this time, confirm that the shim (D) does not interfere with the joint (B). 2. Rack limit adjustment (amp-equipped type) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side and set the pump speed at No r/min. (3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join.
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N=900r/min R=R1(11.2)mm VR=2+-0.01V
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