101603-4350 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034350 1156019102

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-4350 1016034350

ISUZU 1156019102 1156019102

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101603-4350 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-4350 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2900

3. GOVERNOR 105931-4130

4. SUPPLY PUMP 105220-4791

5. AUTOM. ADVANCE MECHANIS 105614-3201

6. COUPLING PLATE 105661-0661

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4823

11. Nozzle and Holder 1-15300-104-2

12. Open Pre:MPa(Kqf/cm2) 18.1(185)

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101442-0101 as _

101603-4350 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-4350 1016034350

ISUZU 1156019102 1156019102

Zexel num

Bosch num

Firm num

Name

101603-4350
101603-4351

1156019102 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 * 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 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 11.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 70.7 69.1 72.3

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 9.6+-0.5

Pump speed r/min 260 260 260

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(11.4)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 70.7 69.7 71.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position (R1-0.4)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 76 74.4 77.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 86 86 96

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

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)Torque control stroke: L1 (3)RACK LIMIT
----------
T1=A66 L1=(0.5)mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=42deg+-5deg b=35deg+-3deg

Stop lever angle

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

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

0000001501 VARIABLE TORQUE CONTROL

N:Pump speed (r/min) R:Rack position (mm) Adjusting shim A Guide screw B (c) Nut (d) Nut (e) nut Torque control spring adjustment method for model responding to speed droop [Advice] Confirm that adjusting shim (A) thickness t = 1.3~1.5 mm is assembled before beginning adjustment. (1)Temporary idle lever position setting 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (2)Idling spring adjustment 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (3)Governor spring setting adjustment 1. Temporarily fix so that the governor shaft's guide screw B protrudes L2 (18 mm) from the end of the governor. 2. Set the control lever where it contacts the idle stopper bolt. 3. Increase the speed to Nh2+100 r/min or more. 4. Adjust using the two nuts C and D so that L1 = 0.3+0.5 mm and fix temporarily. 5. Adjust the protrusion L2 of the guide screw (B) so that the rack position at Nh1 is Rh1 and at Nh2 is Rh2. Then fix using the nut (E). 6. Further increase the speed and readjust the two nuts (C) and (D) so that there is no change in L1 until Nf+50 r/min. Then fix temporarily. [Advice] When L1 becomes smaller while speed is increasing to Nf+50 r/min, decrease speed by Nh2+100 r/min. Adjust so that L1 is even smaller, then again increase speed to Nf+50 r/min and confirm that L1 does not change. (4)Full load position setting 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (5)Torque control spring adjustment 1. Set the control lever so that it contacts the full speed stopper bolt. 2. At the specified speed Nf, adjust using the full speed stopper bolt so that governing begins, then fix temporarily. 3. Increase the speed and adjust using the two nuts (C) and (D) so that the rack position Rg can be obtained at the specified speed Ng. Fix temporarily. 4. Decrease the speed and confirm the governing point (the beginning of governing point) at the specified speed Nf. 5. Set the speed at Nf-50 r/min. 6. Measure the torque control stroke (L1) and adjust to the specified stroke (L1) using the shim (A). 7. After completing shim adjustment, repeat the above adjustment using the two nuts. 8. After confirming the specifications Nf and Ng, fix the two nuts (C) and (D). 9. In this condition, increase the speed and confirm that R = 0 can be obtained. (6)Full speed lever position setting 1. Set the control lever so that it contacts the full speed stopper bolt. 2. At the specified speed Nu, adjust using the full speed stopper bolt so that governing begins, then fix temporarily 3. Increase the speed and confirm that the specified rack position Ru can be obtained. 4. Adjust using the full speed stopper bolt so that governing begins at the specified speed Nf, then fix. 5. Confirm that the result is the same as that in '(5) Torque control spring adjustment.' 6. Confirm that the control lever operating angle is within the specifications. (7)Rack limit adjustment 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
----------

----------

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:

(4) VOP (Valve Opening Pressure) Test A. Open the gauge protector valve [0-34500 kPa (0-5000 psi) gauge].B. Increase the pressure until test oil flows from the nozzle tip.C. Write down the VOP. (5) Pressure Loss Test A. Increase the pressure to 690 kPa (100 psi) less than the VOP.B. Close the pump isolator valve (6).C. Use the gauge protector valve (3), [0-34500 kPa (0-5000 psi) gauge] to adjust pressure to 690 kPa (100 psi) less than the VOP.D. After 30 seconds, write down the pressure loss. (6) Adjustment of Valve Opening Pressure If spray characteristics are satisfactory, adjust the valve unseating pressure: Use 7B2591 Cap Wrench (7) to remove the cap. Remove lift screw locknut (8) and loosen lift adjustment screw (9) approximately three turns, so it does not interfere with the pressure adjustment. Loosen pressure adjustment locknut (10).E. Install the nozzle on the 5P4150 Nozzle Tester. F. Use 7B2601 Wrench (11) and adjust the VOP. G. Remove the valve from the nozzle tester and put it in a vise. Install lift adjustment screw locknut (8).H. Use the 6B1655 Wrench to turn lift adjusting screw (9) down lightly against the stem of the fuel valve spring.I. Clamp the needle lift adjustment fixture to the fuel valve body.J. Use a thickness gauge and adjust screw (12) until there is a clearance of 0.43 (.017") between screw (12) and lift adjustment screw (9).K. Hold screw (12) in position with clamping screw (13).L. Remove the thickness gauge and loosen lift adjustment screw (9) until there is 0.3 (.010") clearance between screw (9) and screw (12), after lift screw locknut (8) is tightened with the 7B2587 Wrench. The correct needle lift setting for all valves is 0.177 (.007").Cleaning Needle, Nozzle And Nozzle End Of Flat Seat Valves (Except 1P1795 Master Valves)
(1) Remove cap (1), bonnet (2) or unseating pressure adjusting screw, spring retainer, spring (3) and spring stem (4). Put the correct needle extracting tool (5) through the valve body and tighten over the end of the needle. If the needle is tight, install a new valve service group, or disassemble and clean the valve according to the procedure that follows. (2) If a fuel valve has a chip of scale, metal or foreign material on the seat, this will prevent the needle, from seating on the spray valve nozzle end, and cause the inner surface of the nozzle end and the needle end to become coated with carbon. Put carbon scraper (6) in the needle extracting tool and insert it into the nozzle bore and against the nozzle end; carefully turn the tool one revolution, with a slight pressure to remove the carbon. The cutting surface of scraper (6) has been lapped as perfectly flat and square with the center line of the tool as possible. Unless it remains so, it cannot effectively remove carbon. Handle this tool with care. Two scrapers are provided, so if one becomes marred, the second can be used while another is being obtained.