101603-0750 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030750 1156018540

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-0750 1016030750

ISUZU 1156018540 1156018540

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Cross reference number

ZEXEL 101603-0750 1016030750

ISUZU 1156018540 1156018540

Zexel num

Bosch num

Firm num

Name

101603-0750
101603-4530

1156018540 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1T * 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 3.4 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 -

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.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
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T1=B18 BCL=0.8+-0.1mm
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N3=800r/min C3=(6.4deg) t1=2--sec. t2=2--sec.
----------
N1=1200++r/min N2=1500r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=1.5--deg C2=6.4+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

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

Stop lever angle

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

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

0000001501 RACK SENSOR

(g) rack limit (h) Standard point (i) pump end face (j) Apply red paint. Rack sensor adjustment (154610-0420) 1. Rack limit adjustment (1)Fix the rack at the rack limit position Rl. (2)Attach shim (D) [shim thickness standard (17.5 - R1] to rod (C) and tighten nut (E). (3)Measure the distance X between the end face of the pump and the nut (E), and select a shim (D) so that X = 33-0.2mm. (4)Release the rack, mount the joint (B) and fix. (5)At this time, confirm that the shim (D) does not interfere with the joint (B). 2. Rack limit adjustment (amp-equipped type) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side and set the pump speed at No r/min. (3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join.
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N=900r/min R=R1(11.2)mm VR=2+-0.01V
----------

Timing setting

(1)Pump vertical direction (2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

Start By:a. remove exhaust manifoldb. remove inlet manifoldc. remove fuel injection nozzle assembliesd. remove fuel filtere. remove water temperature regulatorf. remove cylinder head assembly 1. Put cylinder head assembly (1) in position on tool group (A). 2. Put compression on valve spring (2) with tool (C). 3. Remove spring locks (3). 4. Remove tool (C). Remove valve spring cap (2) and valve springs (4). 5. Remove washer (5) and O-ring seal (8) from valve (7).6. Remove seal (6). Remove valve (7). 7. Check the valve spring tension with tool (B). The outer spring force must be 180 9 N (40 2 lb.). The length of the spring under test force must be 27.4 mm (1.08 in.). The free length after test must be 45.2 mm (1.78 in.). The inner spring force must be 68.5 9 N (15.4 2 lb.). The length of the spring under test force must be 23.88 mm (.940 in.). The length after test must be 39.6 mm (1.56 in.).8. Do Steps 1 through 8 again for the remainder of the valves. If the cylinder head is equipped with removable valve guides, refer to module SENB8082-06, System Operating Testing And Adjusting Specifications, 4.236 And 4.2482 Diesel Engines For Lift Trucks.Install Valves
1. Put clean engine oil on the valve stems.2. Install valve (3), washer (2) and seal (1).
The closed coil of the spring must be toward the cylinder head.
3. Install springs (5) and valve spring cap (4). 4. Use tool (A), and put springs under compression, and install O-ring seal on the valve. Exhaust valves have an extra O-ring seal on them.
Locks (6) can be thrown from the valve when tool (A) is released if they are not in their correct position on the valve stem.
5. Use tool (B), and install locks (6) that hold the springs in place.6. Remove tool (A), and hit the top of the valve with a plastic hammer to be sure the locks are in their correct position on the valve.7. Do Steps 1 through 6 again for the remainder of the valves.End By:a. install cylinder head assemblyb. install water temperature regulatorc. install fuel filterd. install fuel injection nozzle assembliese. install inlet manifold