101603-4180 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034180 1156018932


101603-4180 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-4180 1016034180
ISUZU 1156018932 1156018932

Cross reference number

ZEXEL 101603-4180 1016034180
ISUZU 1156018932 1156018932


Zexel num
Bosch num
Firm num
Name
101603-4180 
 
1156018932  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1 * 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   10.9
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   60.3 58.7 61.9
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   325 325 325
Average injection quantity mm3/st.   8.7 7.4 10
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(10.9)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   60.3 59.3 61.3
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.1
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   65.2 63.6 66.8
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.05
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   64 62.4 65.6
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1(10.9)
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   46.9 45.3 48.5
Fixing the lever   *
Timer adjustment
Pump speed r/min   1050--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1000
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1300
Advance angle deg.   1.8 1.3 2.3
Timer adjustment_04
Pump speed r/min   1600
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-4180
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL
----------
T1=19 RAL=13.6+0.2mm
----------

Speed control lever angle

Test data 101603-4180
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=39deg+-5deg b=39deg+-3deg

Stop lever angle

Test data 101603-4180
N:Pump normal S:Stop the pump.
----------

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

0000001501 TAMPER PROOF

Test data 101603-4180
Tamper proof adjustment (1)Set the full load screw at rack position Ra+0.4. (2)Set the full load position Ra using screw (A).
----------
Ra=R1(10.9)mm
----------

Timing setting

Test data 101603-4180
(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=14deg
----------
a=(60deg)




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