101601-8590 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016018590 1156015272

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-8590 1016018590

ISUZU 1156015272 1156015272

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Cross reference number

ZEXEL 101601-8590 1016018590

ISUZU 1156015272 1156015272

Zexel num

Bosch num

Firm num

Name

101601-8590
101601-8591

1156015272 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 *

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

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

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=39deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

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

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)-
----------
aa=14deg
----------
a=(60deg)

Information:

1. Disconnect the batteries. 2. Remove top panel (1), front panel (2) and the rear panel from the enclosure. 3. Remove the bolt holding ground wires (5) to the frame. Remove wire ties (4) to separate the ground wires. Remove two screws and cover (3). 4. Remove three bolts (7) to disconnect the power bars from the main circuit breaker. Remove the insulation material from power bar (6). Remove bolts (8) holding ground bar (9) to the panel. Put identification on the wires for assembly purposes.5. Disconnect wires (10) from the terminal strip. Disconnect wires (11) from the voltage regulator. 6. Disconnect wires (12) from the inside of the control panel. 7. Remove bolts (13) and disconnect the small gage wire from each power bar. 8. Disconnect wire loom (14) from the generator housing and from the inside of the enclosure at three places. Remove the bolts and lower panel (15). Be sure all wires are free from the enclosure 9. Attach tooling (A) and a hoist to the enclosure as shown. Remove four bolts that fasten the enclosure to the base. Remove the enclosure. The weight of the enclosure is 1258 kg (570 lb.). The following steps are for the installation of the control panel enclosure.10. Use a hoist and tooling (A) to put the enclosure in position on the base. Install the four bolts that hold it to the base.11. Connect wire loom (14) to the generator housing and to the inside of the enclosure at three places. Install lower panel (15).12. Connect small gage wire to each power bar with bolts (13).13. Connect wires (12) to the inside of the control panel.14. Connect wires (10) to the terminal strip. Connect wires (11) to the voltage regulator.15. Connect ground bar (9) to the panel with two bolts (8). Wrap insulation material around power bar (6). Connect the power bars to the main circuit breaker with three bolts (7).16. Connect ground wires (5) to the frame and install wire ties (4) to hold the wires together. Install cover (3) with two screws.17. Install the rear, front and top panels on the enclosure.18. Connect the batteries.Remove Control Panel Enclosure (Standby)
The photographs shown are of a 3306B Standby Generator. The procedure is the same for the 3406B Standby Generator. 1. Remove door (1).2. Remove two bolts (2) from cover (3). 3. Remove doors (4).4. Remove fourteen bolts (7) and cover (5).5. Remove the battery charger. See the topic, Remove And Install Battery Charger.6. Remove the bolts and cover (6).7. Remove the three bolts located above the control panel and remove cover (3). 8. Identify and disconnect all the wires from breaker (9) and grounding buss (10).9. Remove bolts (8), bracket (11), and breaker (9). 10. Identify and disconnect all wires (12) between the generator and the control panels from the terminal strips on the control panels.11. Identify and disconnect all wires between the engine and control panels from the terminal strips on the control panels.12. Remove bolts (13). 13.