101603-8660 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038660 8943959801

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-8660 1016038660

ISUZU 8943959801 8943959801

Service parts 101603-8660 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6310

3. GOVERNOR 105932-1140

4. SUPPLY PUMP 105210-6090

5. AUTOM. ADVANCE MECHANIS 105643-1030

6. COUPLING PLATE 105661-1140

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4282

11. Nozzle and Holder 8-94395-511-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105030-4700

14. NOZZLE 105025-0530

15. NOZZLE SET

Include in #1:

101401-4200 as _

101603-8660 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-8660 1016038660

ISUZU 8943959801 8943959801

Zexel num

Bosch num

Firm num

Name

101603-8660
101603-8661

8943959801 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1 * 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 12.6

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 80 78.4 81.6

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 H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

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 850 850 850

Average injection quantity mm3/st. 80 79 81

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(12.6)

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 88.5 84.5 92.5

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. 67.5 64.3 70.7

Fixing the lever *

Timer adjustment

Pump speed r/min 1200

Remarks
Measure the actual advance angle.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 5.5 5 6

Remarks
Measure the actual speed, stop

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.
----------
T1=K49
----------

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=14deg+-5deg b=40deg+-3deg

Stop lever angle

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

1. (1) Set the speed lever to idle. (2)Screw in air cylinder (A) (3)Set the clearance from the speed lever (B) at approximately L.
----------
L=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)At rack position = bb
----------
aa=6deg bb=12.6mm
----------
a=(150deg)