101603-8400 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038400 8943955720

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-8400 1016038400

ISUZU 8943955720 8943955720

Cross reference number

ZEXEL 101603-8400 1016038400

ISUZU 8943955720 8943955720

Zexel num

Bosch num

Firm num

Name

101603-8400
101603-8401

8943955720 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1-S * 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)
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 4.7 4.65 4.75

Rack position
After adjusting injection quantity. 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 12.9

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 84 82.4 85.6

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 275 275 275

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(12.9)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 84 83 85

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 94.5 91.3 97.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 75 71.8 78.2

Fixing the lever *

Timer adjustment

Pump speed r/min 905--

Advance angle deg. 0 0 0

Load 3/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 855

Advance angle deg. 0.3

Load 3/5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1110

Advance angle deg. 1.5 1 2

Load 3/5

Timer adjustment_05

Pump speed r/min 1450

Advance angle deg. 7 6.5 7.5

Load 5/5

Remarks
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)Air cylinder operating pressure: P1 or more (4)Air cylinder operating pressure: P2 (5)At delivery (at R = RA, N = N1)
----------
T1=J58 P1=294kPa(3kgf/cm2) P2=0kPa(0kgf/cm2) RA=R1(12.9)mm N1=150r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)When air cylinder OFF. (2)Air cylinder operating pressure: at P1 (3)Use the pin at R = aa (4)Stopper bolt set position 'H' (5)Set the idle side stopper bolt at rack position = bb (at shipping).
----------
P1=294kPa(3kgf/cm2) aa=35mm bb=R1(12.9)mm
----------
a=10deg+-5deg b=39deg+-3deg c=(35deg)+-3deg d=(14deg)

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

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
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PL=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------

0000001601 AIR CYLINDER

(A): Speed lever (B): Speed lever (a): Stopper bolt (b): Nut 1. Air cylinder adjustment procedure (1)Apply positive pressure P1 (ON) to the air cylinder. (2)Operate the speed lever (A). (At this time speed lever (B) also moves together.) (3)At speed N1 and rack position Ra, adjust using stopper bolt (b) so that speed lever (B) is at the stop position and speed lever (A) is in the cancel position. (4)Confirm that the speed lever turns to the full position at positive pressure (OFF) P2. (5)After repeating the above several times, fix the stopper bolt (a) using the nut (b).
----------
P1=294kPa(3kgf/cm2) P2=0kPa(0kgf/cm2) N1=1450r/min Ra=12+-0.1mm
----------

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=6deg
----------
a=(150deg)