101603-8480 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038480 8943957500


101603-8480 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-8480 1016038480
ISUZU 8943957500 8943957500

Service parts 101603-8480 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6211
3. GOVERNOR 105932-0920
4. SUPPLY PUMP 105210-6080
5. AUTOM. ADVANCE MECHANIS 105672-5250
6. COUPLING PLATE 105661-1140
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-7740
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 16.2{165}/18.1{185}
13. NOZZLE-HOLDER 105030-4610
14. NOZZLE 105025-0080
15. NOZZLE SET

Include in #1:

101603-8480 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101603-8480 1016038480
ISUZU 8943957500 8943957500


Zexel num
Bosch num
Firm num
Name
101603-8480 
101603-8481 
 
8943957500  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   13
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   86.5 84.9 88.1
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   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(13)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   86.5 85.5 87.5
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.   95.5 92.3 98.7
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.25
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   77.5 74.3 80.7
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

Test data 101603-8480
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=K09
----------

Speed control lever angle

Test data 101603-8480
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=60mm
----------
a=28.5deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101603-8480
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-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.
----------
PL=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------

0000001601 AIR CYLINDER

Test data 101603-8480
(a) Air cylinder (b) Speed lever (c) Lock nut 1. Air cylinder adjustment procedure (1)Fix the speed lever (b) at the idle side. (2)Screw in the air cylinder (a) (3)Set the clearance between the speed lever (b) and the air cylinder (a) to approximately L1.
----------
L1=1mm
----------

Timing setting

Test data 101603-8480
(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)At rack position = bb
----------
aa=6deg bb=R1(13)mm
----------
a=(150deg)




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