101603-8072 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038072 8943938533


101603-8072 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-8072 1016038072
ISUZU 8943938533 8943938533

Service parts 101603-8072 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6120
3. GOVERNOR 105931-9102
4. SUPPLY PUMP 105210-5110
5. AUTOM. ADVANCE MECHANIS 105643-0860
6. COUPLING PLATE 105661-1101
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-7182
11. Nozzle and Holder 8-94394-906-0
12. Open Pre:MPa(Kqf/cm2) 18.1{185}/22.1{225}
13. NOZZLE-HOLDER 105048-3882
14. NOZZLE
15. NOZZLE SET 105019-1020

Include in #1:

101603-8072 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101603-8072 1016038072
ISUZU 8943938533 8943938533


Zexel num
Bosch num
Firm num
Name
101603-8072 
101603-8073 
 
8943938533  ISUZU
INJECTION-PUMP ASSEMBLY
6HE1-TC2 * 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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
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
Beginning of injection position
Governor 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   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
 
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
 

Test data Ex:

Governor adjustment

Test data 101603-8072
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
----------

Speed control lever angle

Test data 101603-8072
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

Stop lever angle

Test data 101603-8072
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg

Timing setting

Test data 101603-8072
(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




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