101603-4554 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034554 1156022655


101603-4554 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-4554 1016034554
ISUZU 1156022655 1156022655

Cross reference number

ZEXEL 101603-4554 1016034554
ISUZU 1156022655 1156022655


Zexel num
Bosch num
Firm num
Name
101603-4554 
101603-4557 
 
1156022655  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1S *

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   11.6
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   74.8 73.2 76.4
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   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(11.6)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   74.8 73.8 75.8
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.35
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   87.3 83.3 91.3
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   93 93 101
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1275--
Advance angle deg.   0 0 0
Load   3/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1225
Advance angle deg.   0.5
Load   3/4
Timer adjustment_03
Pump speed r/min   1275
Advance angle deg.   0.5
Load   4/4
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   5.5 5 6
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-4554
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C90
----------

Speed control lever angle

Test data 101603-4554
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=40mm
----------
a=42deg+-5deg b=38deg+-3deg

Stop lever angle

Test data 101603-4554
N:Pump normal S:Stop the pump.
----------

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

0000001501 RACK SENSOR

Test data 101603-4554
V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------

0000001601 RACK SENSOR

Test data 101603-4554
(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=900r/min Ra=R1(11.6)mm
----------

Timing setting

Test data 101603-4554
(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)




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Group cross 101603-4554 ZEXEL

Isuzu 

 
1156022651 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022652 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022653 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022654 
INJECTION-PUMP ASSEMBLY
6BG1
101603-4554  

101603-4557 
 
1156022655 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022656 
INJECTION-PUMP ASSEMBLY
6BG1-S
 
1156022657 
INJECTION-PUMP ASSEMBLY
6BG1-S
9 400 615 088 
 
INJECTION-PUMP ASSEMBLY
6BG1-S

Isuzu 

9 400 615 088 
1156022658 
INJECTION-PUMP ASSEMBLY
6BG1-S
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