101603-4802 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034802 1156023282

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-4802 1016034802

ISUZU 1156023282 1156023282

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Service parts 101603-4802 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4590

3. GOVERNOR 105931-4981

4. SUPPLY PUMP 105220-4791

5. AUTOM. ADVANCE MECHANIS 105644-0350

6. COUPLING PLATE 105661-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6241

11. Nozzle and Holder 1-15300-142-0

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-5860

15. NOZZLE SET

Include in #1:

101603-4802 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-1482 as _

Cross reference number

ZEXEL 101603-4802 1016034802

ISUZU 1156023282 1156023282

Zexel num

Bosch num

Firm num

Name

101603-4802

1156023282 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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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

Rack position
Point A 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 10.8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 54.3 52.7 55.9

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 290 290 290

Average injection quantity mm3/st. 8 6.7 9.3

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(10.8)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 54.3 53.3 55.3

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10.8)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 60 56.8 63.2

Fixing the lever *

Timer adjustment

Pump speed r/min 1310--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1260

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1
----------
T1=C78
----------

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=(33deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Stopper bolt setting
----------

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

0000001501 ACS

(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=900r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.8)mm Rb=R1-0.5mm Pa=84.5+-2.7kPa(634+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=54.3+-1cm3/1000st Q2=(40.4)+-1.6cm3/1000st

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=13deg
----------
a=(60deg)

Information:

Illustration 39 g00367353
Set the drive speed to "Col 4". Place a straight edge across the opening in the shutdown rod and the shutdown rod nut (F). Use a 7/16 inch open end wrench in order to turn the shutdown rod nut (F) counterclockwise until the governor begins to shut down. Once the governor begins to shut down, turn the nut clockwise one full turn.Adjustment Of The Shutdown Device
Note: The electric shutdown device and the pressure shutdown device should be checked prior to the installation, after the installation, and at 1000 hour intervals thereafter.
Failure to test, inspect and maintain these items could result in faulty operation and possible severe engine damage if an emergency shutdown situation occurs.
The electric shutdown is either an Energize-To-Shutoff (ETS) or an Energize-To-Run (ETR). Identify the type of shutdown device in your governor, and make a note of the type of shutdown device.
Visually inspect the pressure shutdown components for signs of burrs, nicks, scoring and/or wear. Repair the components if evidence of a problem exists. Inspect the pressure shutdown gasket. Determine if the gasket is reusable. If necessary, replace the gasket.
Illustration 40 g00367319
(F) Shutdown Rod Nut. (J) Shutdown Rod. (II) Solenoid. (JJ) Jam Nut. (KK) Set Screw. (LL) Shutdown Plunger. (MM) Solenoid Plunger. (NN) Pivot Pin. (PP) Shutdown Lever.
Visually inspect the electric shutdown device and determine if there is any component wear. If the shutdown is an ETS version, pay particular attention to the connection of the shutdown solenoid's plunger and the shutdown lever's link pin.If there is evidence of wear, replace the solenoid. Inspect the gasket on the electric shutdown. Determine if the gasket is reusable. If necessary, replace the gasket.Check the size of spacer on the solenoid plunger in the electric shutdown. Refer to the Service Magazine Article November 19,, "Field Replacement of Spacer to Correct Possible Sticking in Woodward 3161 Governor Electric Shutoff Group".Adjustment Of The Electric Shutdown Solenoid
Energize-To-Shutoff (ETS)
Place the housing of the electric shutdown in a vise. Use copper jaws or shop towels in order to protect the sides of the aluminum die cast housing. Do NOT excessively tighten the vise.Loosen the jam nut (JJ) that holds the solenoid in the electric shutdown's housing. Remove the solenoid coil (II) in order to expose the shutdown plunger (MM) .Note: Loctite 222 is used on the threads of the solenoid coil during manufacturing. In addition, the jam nut is tightened to a torque of 75 N m (55.5 lb ft).
Carefully clean any dirt, metal filings or metal chips from the solenoid plunger and from the cavity in the solenoid coil. Turn the jam nut on the solenoid coil so that the nut will not interfere with the adjustment of the solenoid coil. Reinstall the solenoid coil in the electric shutdown's housing by turning the coil four times.
Hold the housing and the gasket on a