101603-8992 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038992 8943906046


101603-8992 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-8992 1016038992
ISUZU 8943906046 8943906046

Service parts 101603-8992 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6570
3. GOVERNOR 105932-2583
4. SUPPLY PUMP 105230-1090
5. AUTOM. ADVANCE MECHANIS 105690-0222
6. COUPLING PLATE 105661-1170
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-7743
11. Nozzle and Holder 8-94391-291-4
12. Open Pre:MPa(Kqf/cm2) 16.2{165}/19.6{200}
13. NOZZLE-HOLDER 105041-2082
14. NOZZLE
15. NOZZLE SET 105019-2190

Include in #1:

101603-8992 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-8992 1016038992
ISUZU 8943906046 8943906046


Zexel num
Bosch num
Firm num
Name
101603-8992 
101603-8993 
 
8943906046  ISUZU
INJECTION-PUMP ASSEMBLY
6HL1-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   105780-8260
Bosch type code   9 430 610 133
Nozzle   105780-0120
Bosch type code   1 688 901 990
Nozzle holder   105780-2190
Opening pressure MPa   18
Opening pressure kgf/cm2   184
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   6-2-600
Overflow valve   131424-8620
Overflow valve opening pressure kPa   206 172 240
Overflow valve opening pressure kgf/cm2   2.1 1.75 2.45
Tester oil delivery pressure kPa   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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   3.8 3.75 3.85
Rack position
Point A
  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   14.5
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   133.5 131.9 135.1
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   Z
Rack position   9.5+-0.5
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   15.5 14.2 16.8
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(14.5)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   133.5 132.5 134.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   [R1+1.05 ]+0.05-0 .15
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   133 129.8 136.2
Fixing the lever   *

Test data Ex:

Governor adjustment

Test data 101603-8992
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=N14
----------

Timer adjustment

Test data 101603-8992
(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C2=(8)deg t1=2--sec. t2=2--sec.
----------
N1=1300++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

Test data 101603-8992
F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt setting (3)Viewed from feed pump side.
----------
aa=35mm
----------
a=10deg+-5deg b=41deg+-3deg

Stop lever angle

Test data 101603-8992
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg

0000001501 RACK SENSOR

Test data 101603-8992
Rack sensor adjustment 1. Flange type rack sensor (rack sensor adjustment -5*20) (1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures. (2)Mount the rack sensor main body to the pump main body. (3)Fix the pump lever at full. (4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist. (5)Move the pump lever two or three times. (6)Set again to full. (7)Confirm that the amplifier output voltage is Vist. (8)Fix the caution plate to the upper part of the rack sensor. (For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.) (9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=850r/min Ra=R1(14.5)mm Vist=3.74+-0.28V
----------

Timing setting

Test data 101603-8992
(1)Pump vertical direction (2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=6deg
----------
a=(160deg)




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101603-8992  

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6HL1-S
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