101603-0530 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030530 1156017751


101603-0530 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-0530 1016030530
ISUZU 1156017751 1156017751

Cross reference number

ZEXEL 101603-0530 1016030530
ISUZU 1156017751 1156017751


Zexel num
Bosch num
Firm num
Name
101603-0530 
 
1156017751  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1TC * 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   3.6 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   13.8
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   89.9 88.3 91.5
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(13.8)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   89.9 88.9 90.9
Basic   *
Fixing the lever   *
Boost pressure kPa   20 20
Boost pressure mmHg   150 150
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.45
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   89.2 86 92.4
Fixing the lever   *
Boost pressure kPa   20 20
Boost pressure mmHg   150 150
Injection quantity adjustment_05
Adjusting point   C
Rack position   R-0.1
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   83.8 80.6 87
Fixing the lever   *
Boost pressure kPa   20 20
Boost pressure mmHg   150 150
Injection quantity adjustment_06
Adjusting point   D
Rack position   12.6
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   54.5 52.9 56.1
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_07
Adjusting point   I
Rack position   15+-0.5
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   92 92 100
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   550 550 550
Rack position   12.6
Boost pressure kPa   2 2 4.7
Boost pressure mmHg   15 15 35
Boost compensator adjustment_02
Pump speed r/min   550 550 550
Rack position   13.1
Boost pressure kPa   4.7 4.7 7.4
Boost pressure mmHg   35 35 55
Boost compensator adjustment_03
Pump speed r/min   550 550 550
Rack position   R1-0.1
Remarks
Measure actual boost pressure.
 
Timer adjustment
Pump speed r/min   1325--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1275
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   1 0.5 1.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-0530
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B04 BCL=(1.1)+-0.1mm
----------

Speed control lever angle

Test data 101603-0530
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=43deg+-5deg b=41deg+-3deg

Stop lever angle

Test data 101603-0530
N:Pump normal S:Stop the pump.
----------

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

0000001501 RACK SENSOR

Test data 101603-0530
V1:Output voltage Vf:Full side output voltage F:Full-speed I:Idle (a) Speed lever (B) Full side stopper bolt (c) Nut (d) Nut (e) nut (P) Potentiometer 1. Load sensor adjustment (1)Apply voltage V to between the potentiometer (P)'s connector terminals (1) ~ (3) and measure the output voltage between (1) ~ (2). (2)Move the speed lever (A) until it contacts the full side stopper bolt (B) and then turn the nut (D) to adjust the potentiometer (P)'s output voltage to Vf. (3)Confirm that the speed lever (A) turns smoothly between idle and Full side, then fix using nut (E). (Tightening torque: 4.4~7N.m{0.5~0.7kgf.m}) (4)Move the speed lever (A) several times to contact full side stopper bolt (B) and confirm that the potentiometer (P) output voltage is Vf. (5)Confirm that the speed lever (A) turns smoothly between idle and Full (b deg).
----------
V=DC24V Vf=16+-0.1V
----------

Timing setting

Test data 101603-0530
(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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