101603-8490 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038490 8943957510


101603-8490 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-8490 1016038490
ISUZU 8943957510 8943957510

Service parts 101603-8490 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6211
3. GOVERNOR 105932-0910
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 8-94393-335-1
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:

101603-8490 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101603-8490 1016038490
ISUZU 8943957510 8943957510


Zexel num
Bosch num
Firm num
Name
101603-8490 
101603-8491 
 
8943957510  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 101603-8490
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 101603-8490
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=14deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101603-8490
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%
----------

Timing setting

Test data 101603-8490
(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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