101603-4520 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034520 1156022690


101603-4520 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-4520 1016034520
ISUZU 1156022690 1156022690

Cross reference number

ZEXEL 101603-4520 1016034520
ISUZU 1156022690 1156022690


Zexel num
Bosch num
Firm num
Name
101603-4520 
101603-4522 
 
1156022690  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1T *

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   H
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
Basic   *
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.
 
Timer adjustment
Pump speed r/min   1300--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1250
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1350
Advance angle deg.   0.7 0.2 1.2
Timer adjustment_04
Pump speed r/min   1450
Advance angle deg.   1.5 1.2 1.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-4520
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=C15 BCL=0.8+-0.1mm
----------

Speed control lever angle

Test data 101603-4520
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=40deg+-5deg b=34deg+-3deg

Stop lever angle

Test data 101603-4520
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101603-4520
(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)




Have questions with 101603-4520?





Group cross 101603-4520 ZEXEL

Isuzu 

 
1156022680 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156022681 
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6BG1-TC
 
1156022510 
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6BG1
 
1156022511 
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6BG1
 
1156022512 
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9 400 615 086 
1156022513 
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101603-4520  

101603-4522 
 
1156022690 
INJECTION-PUMP ASSEMBLY
6BD1T
 
1156022691 
INJECTION-PUMP ASSEMBLY
6BD1T
9 400 615 087 
 
INJECTION-PUMP ASSEMBLY
6BD1-T

Isuzu 

9 400 615 087 
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1156022700 
INJECTION-PUMP ASSEMBLY
6BD1T
 
1156022710 
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6BD1T
 
1156022711 
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6BD1T
 
1156022712 
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6BD1-T
 
1156022651 
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6BG1
 
1156022652 
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6BG1
 
1156022653 
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6BG1
 
1156022654 
INJECTION-PUMP ASSEMBLY
6BG1
 
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
 
1156023000 
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6SA1
 
1156023001 
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6SA1
 
1156022490 
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6BG1S
 
1156022491 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022492 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022493 
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6BG1-S
 
1156022500 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022501 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022502 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022503 
INJECTION-PUMP ASSEMBLY
6BG1-S
 
1156022520 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022521 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022522 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022523 
INJECTION-PUMP ASSEMBLY
6BG1S
9 400 615 089 
 
INJECTION-PUMP ASSEMBLY
6BG1-S

Isuzu 

9 400 615 089 
1156022524 
INJECTION-PUMP ASSEMBLY
6BG1-S
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