101603-7560 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037560 1156026910


101603-7560 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-7560 1016037560
ISUZU 1156026910 1156026910

Cross reference number

ZEXEL 101603-7560 1016037560
ISUZU 1156026910 1156026910


Zexel num
Bosch num
Firm num
Name
101603-7560 
101603-7564 
 
1156026910  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-TC2 *

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)
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   4.9 4.85 4.95
Rack position
After adjusting injection quantity.
  R=A
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   13
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   88.8 87.2 90.4
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(13)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   88.8 87.8 89.8
Basic   *
Fixing the lever   *
Boost pressure kPa   30.7 30.7
Boost pressure mmHg   230 230
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(13)
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   95.9 92.7 99.1
Fixing the lever   *
Boost pressure kPa   30.7 30.7
Boost pressure mmHg   230 230
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2(R1-0. 5)
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   75.2 72 78.4
Fixing the lever   *
Boost pressure kPa   30.7 30.7
Boost pressure mmHg   230 230
Injection quantity adjustment_06
Adjusting point   D
Rack position   R2-1.3
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   52.5 49.3 55.7
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.   96 96 128
Fixing the lever   *
Boost compensator adjustment
Pump speed r/min   550 550 550
Rack position   R2-1.3
Boost pressure kPa   5.3 5.3 8
Boost pressure mmHg   40 40 60
Boost compensator adjustment_02
Pump speed r/min   550 550 550
Rack position   R2(R1-0. 5)
Boost pressure kPa   17.3 17.3 17.3
Boost pressure mmHg   130 130 130
Timer adjustment
Pump speed r/min   1200--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1150
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   3 2.5 3.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-7560
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke
----------
T1=F20
----------

Speed control lever angle

Test data 101603-7560
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=44mm
----------
a=43deg+-5deg b=39deg+-3deg

Stop lever angle

Test data 101603-7560
N:Pump normal S:Stop the pump.
----------

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

0000001501 RACK SENSOR

Test data 101603-7560
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 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.
----------
PL=131153-5520 ST=A734 L1=1mm L2=4.9+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

Test data 101603-7560
(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=11deg
----------
a=(60deg)




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Group cross 101603-7560 ZEXEL

Isuzu 

101603-7560  

101603-7564 
 
1156026910 
INJECTION-PUMP ASSEMBLY
6BG1-TC2
 
1156026911 
INJECTION-PUMP ASSEMBLY
6BG1-TC2
 
1156026912 
INJECTION-PUMP ASSEMBLY
6BG1-TC2
 
 
INJECTION-PUMP ASSEMBLY

Isuzu 

9 400 615 195 
1156026913 
INJECTION-PUMP ASSEMBLY
6BG1-TC2
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