101603-7380 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037380 1156026230

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-7380 1016037380

ISUZU 1156026230 1156026230

Cross reference number

ZEXEL 101603-7380 1016037380

ISUZU 1156026230 1156026230

Zexel num

Bosch num

Firm num

Name

101603-7380
101603-7381

1156026230 ISUZU

INJECTION-PUMP ASSEMBLY
6SA1-T *

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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.7 3.65 3.75

Rack position
After adjusting injection quantity. R=A

Beginning of injection position
Governor 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 800 800 800

Average injection quantity mm3/st. 105.8 104.2 107.4

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 290 290 290

Average injection quantity mm3/st. 10 8 12

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 800 800 800

Average injection quantity mm3/st. 105.8 104.8 106.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.5

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 96.1 92.9 99.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.45

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 72.3 69.1 75.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95.5 95.5 127.5

Fixing the lever *

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1250

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
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T1=E40
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=18deg+-5deg b=27deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Upper lever angle (2)Engine normal (3)Stopper bolt setting (4)Bottom lever
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a=25deg+-5deg b=40deg+-5deg c=(11deg)

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
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PL=131153-4020 ST=A719 L1=1mm L2=3.7+-0.05mm a1=+-14% a2=+-2.5%
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0000001601 ACS

(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 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)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
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N1=800r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
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Ra=R1(11.6)mm Rb=(R1-0.3)mm Pa=77.3+-2.7kPa(580+-20mmHg) Pb=65.3+-0.7kPa(490+-5mmHg) Q1=105.8+-1cm3/1000st Q2=90.7+-1.6cm3/1000st

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)-
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aa=10deg
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a=(40deg)