Rating:
Information injection-pump assembly
ZEXEL
101603-8072
1016038072
ISUZU
8943938533
8943938533
Service parts 101603-8072 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94394-906-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}/22.1{225}
14.
NOZZLE
Include in #1:
101603-8072
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-5130
as _
Cross reference number
ZEXEL
101603-8072
1016038072
ISUZU
8943938533
8943938533
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.5
3.45
3.55
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
99.4
97.8
101
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
260
260
260
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(12.6)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
99.4
98.4
100.4
Basic
*
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(12.6)
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
105.5
102.3
108.7
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-1.25
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
73.6
70.4
76.8
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
102
102
134
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
900
900
900
Rack position
R1-1.25
Boost pressure
kPa
5.3
4
6.6
Boost pressure
mmHg
40
30
50
Boost compensator adjustment_02
Pump speed
r/min
900
900
900
Rack position
R1(12.6)
Boost pressure
kPa
12.7
6
19.4
Boost pressure
mmHg
95
45
145
Timer adjustment
Pump speed
r/min
1175--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1125
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
3.5
3
4
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Adjust so that the boost compensator pushrod protrusion R = Ra at 0 boost.
(4)Boost compensator stroke: BCL
----------
T1=H66 Ra=12+-0.5mm BCL=1.25+-0.1mm
----------
----------
T1=H66 Ra=12+-0.5mm BCL=1.25+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=53mm
----------
a=10deg+-5deg b=(37deg)+-3deg
----------
aa=53mm
----------
a=10deg+-5deg b=(37deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
----------
aa=45mm
----------
a=12.5deg+-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)-
(5)Pump vertical direction
(6)Direction of rotation
(7)Pointer
(8)Pointer stamping
(9)Timing device stamping
(10)Timing device
(11)Move b deg and stamp both at the same time as shown above.
(12)Outside circumference of timing device
(13)Secondary timing stamping position for the No. 1 cylinder's beginning of injection
----------
aa=12deg
----------
a=(160deg) b=0deg30min
----------
aa=12deg
----------
a=(160deg) b=0deg30min