101603-0830 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030830 1156018710


 

Information injection-pump assembly

ZEXEL 101603-0830 1016030830
ISUZU 1156018710 1156018710
101603-0830 INJECTION-PUMP ASSEMBLY
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Service parts 101603-0830 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-2710
3. GOVERNOR 105931-3510
4. SUPPLY PUMP 105220-4781
5. AUTOM. ADVANCE MECHANIS 105612-3190
6. COUPLING PLATE 105661-0681
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6060
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 18.1(185)
13. NOZZLE-HOLDER 105031-3930
14. NOZZLE 105015-5730
15. NOZZLE SET

Include in #1:

101603-0830 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-0830 1016030830
ISUZU 1156018710 1156018710


Zexel num
Bosch num
Firm num
Name
101603-0830 
 
1156018710  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1T * K 14BE PE6A PE

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 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
Rack position
After adjusting injection quantity.
  R=A
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   950 950 950
Average injection quantity mm3/st.   71.4 69.8 73
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   275 275 275
Average injection quantity mm3/st.   10 8.7 11.3
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(13.8)
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   71.4 70.4 72.4
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.2
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   77.4 74.2 80.6
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.15
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   75.8 72.6 79
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1-0.45
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   45 41.8 48.2
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   I
Rack position   15.7+-0. 5
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   74 74 79
Fixing the lever   *
Rack limit   *
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.   0.9 0.4 1.4
Timer adjustment_04
Pump speed r/min   1600
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-0830
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=A31
----------

Speed control lever angle

Test data 101603-0830
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=34deg+-5deg b=41deg+-3deg

Stop lever angle

Test data 101603-0830
N:Pump normal S:Stop the pump.
----------

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

0000001501 ACS

Test data 101603-0830
(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(13.8)mm Rb=R1-0.2mm Pa=89.4+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=71.4+-1cm3/1000st Q2=(68)+-1.6cm3/1000st

Timing setting

Test data 101603-0830
(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=10deg
----------
a=(60deg)




Information:

Safety is everyone's business and is basically the use of good common sense. A general guide of safety precautions are given below, but each installation has its own peculiarities which cannot always be predicted and covered by established rules. Past experience and common sense are needed for the necessary safety measures. Attention to safety will help avoid serious accidents. Be alert. Watch for hazards. Use preventive measures. Correct deficiencies immediately.The following safety precautions are a general guide to safe operation:1. To prevent personal injury, install guards over all exposed rotating parts.2. To prevent hearing damage, wear ear protective devices if working inside an enclosed engine room with engine running.3. To prevent head injury, wear safety hat when working in the area of overhead equipment.4. Wear safety glasses and shoes as required. 5. Do not wear loose clothing whenever working around engines or machinery.6. Wipe up spilled oil, fuel or coolant.7. Keep batteries in a well ventilated area. Do not smoke around batteries. Hydrogen gas, which is present in the area of the batteries, is highly explosive.8. Provide adequate and safe waste oil disposal.9. Store oily rags in fireproof containers. Don't leave rags on engine.
When using pressure air, wear safety glasses and protective clothing. Maximum air pressure, used for cleaning, must be below 30 PSI (2 kg/cm2).
10. Remove all tools, electrical cords and other loose items from the engine before starting.11. Disconnect and tape the battery ground lead before working on an engine to prevent accidental starting. Be sure an automatic start-stop system cannot operate and start the engine while working on it.12. Do not attempt repairs you do not understand. Follow instructions.13. Stop engine before adjusting or repairing engine or driven equipment.14. Remove radiator cap slowly. Cooling systems can be pressurized and hot fluid will flash to steam as pressure is removed.15. Never start an engine with the governor linkage disconnected.16. Replace or repair broken or damaged equipment. Use proper tools.17. Do not smoke while refueling. Observe NO SMOKING signs.18. Never store flammable liquids near the engine.19. All electrical equipment must be grounded according to local building codes.20. Check all connections periodically for tightness and insulation.21. Insulate all connections and disconnected wires.22. Do not use carbon tetrachloride fire extinguishers. Fumes are toxic and the liquid has a deteriorating effect on insulation. 23. Do not touch the heat sink on the generator regulator when the generator is running. It is electrically "hot".24. Do not work on electrically "hot" equipment.25. Always disconnect the engine starter circuit when working on the generator.26. Hot engine oil can cause burns when drained. Allow the oil to cool below 140°F or provide protection when draining the hot oil.27. Never remove a plug to check pressure with the engine running. Shut down the engine and assure there is no pressure before removing plug.28. When starting an engine after repair, make provisions for shutting off air supply in case there is an overspeed on start up.29. Never look into an open cylinder port and turn over

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Group cross 101603-0830 ZEXEL

Isuzu 

 
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