Rating:
Information injection-pump assembly
ZEXEL
101603-8210
1016038210
ISUZU
1156029000
1156029000
Service parts 101603-8210 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-105-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101603-8210
as INJECTION-PUMP ASSEMBLY
Include in #2:
104749-5180
as _
Cross reference number
ZEXEL
101603-8210
1016038210
ISUZU
1156029000
1156029000
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.4
3.35
3.45
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.25 60.25
Cal 1-5 deg. 60 59.25 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.25 120.25
Cal 1-3 deg. 120 119.25 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.25 180.25
Cal 1-6 deg. 180 179.25 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.25 240.25
Cyl.1-2 deg. 240 239.25 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.25 300.25
Cal 1-4 deg. 300 299.25 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
11
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
75.5
73.9
77.1
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
290
290
290
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
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11)
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
75.5
74.5
76.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
22.7
22.7
Boost pressure
mmHg
170
170
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.25
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
80.5
77.3
83.7
Fixing the lever
*
Boost pressure
kPa
22.7
22.7
Boost pressure
mmHg
170
170
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-0.
5)
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
48.9
45.7
52.1
Fixing the lever
*
Boost pressure
kPa
22.7
22.7
Boost pressure
mmHg
170
170
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
80
80
85
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R2-0.5
Boost pressure
kPa
4.7
4.7
7.4
Boost pressure
mmHg
35
35
55
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R2-0.25
Boost pressure
kPa
8
6.7
9.3
Boost pressure
mmHg
60
50
70
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
R2(R1-0.
5)
Boost pressure
kPa
9.3
9.3
9.3
Boost pressure
mmHg
70
70
70
Timer adjustment
Pump speed
r/min
1300--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1250
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1350
Advance angle
deg.
0.7
0.2
1.2
Timer adjustment_04
Pump speed
r/min
1450
Advance angle
deg.
1.5
1.2
1.8
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)RACK LIMIT
(4)Boost compensator stroke: BCL
----------
T1=C15 BCL=0.5+-0.1mm
----------
----------
T1=C15 BCL=0.5+-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=35mm
----------
a=41.5deg+-5deg b=34deg+-3deg
----------
aa=35mm
----------
a=41.5deg+-5deg b=34deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-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)-
----------
aa=16deg
----------
a=(60deg)
----------
aa=16deg
----------
a=(60deg)