101603-8020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038020 8943937140

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-8020 1016038020

ISUZU 8943937140 8943937140

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Cross reference number

ZEXEL 101603-8020 1016038020

ISUZU 8943937140 8943937140

Zexel num

Bosch num

Firm num

Name

101603-8020
101603-8021

8943937140 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1-N * 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 3.4 3.35 3.45

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 11.1

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 66.5 64.9 68.1

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 H

Rack position 9.5+-0.5

Pump speed r/min 265 265 265

Average injection quantity mm3/st. 8.7 7.4 10

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(11.1)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 66.5 65.5 67.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.7

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 86.3 83.1 89.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 100 100 108

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 3 2.5 3.5

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)RACK LIMIT
----------
T1=G60
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=10deg+-5deg b=34deg+-3deg

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 ACS

(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=900r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(11.1)mm Rb=(R1-0.7)mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=66.5+-1cm3/1000st Q2=47+-1.6cm3/1000st

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=14deg
----------
a=(150deg)

Information:

2. Loosen bolts (3) from the belt tightener bracket. Remove belts (2) from the fan drive.3. Disconnect the fan drive lubrication tube from the support block.4. Remove nuts (1) from the fan drive bracket. Remove the fan drive from the pump drive cover studs.Install Fan Drive
1. Put fan drive (1) in position on pump drive cover studs (4). Install the nuts that hold the fan drive.2. Connect lubrication line (2) to support block (3).3. Install the belts on the fan drive, crankshaft pulley and belt tightener bracket. Tighten the belts to have an adjustment of belt deflection (movement) to 7/8" (22.2 mm) under 25 lb. (110 N) force half way between pulleys.4. Tighten the 5/8" diameter bolt on the belt tightener bracket to a torque of 75 10 lb.ft. (100 14 N m). Tighten the 1/2" diameter bolt to a torque of 40 5 lb.ft. (55 7 N m).5. Install the belts on the alternator and the fan drive. Check the belt deflection (movement) again as in Step 3.end by:a) install fan assemblyDisassemble Fan Drive
start by:a) remove fan drive 1. Remove lubrication tube (1) from the fan drive.2. Remove bolts (3) from fan drive adapter (2). Remove the adapter. 3. Remove bolts (4) and washer (5). Remove seal (6). 4. Remove pulley (9) from bracket (7).5. Remove bearing (11) and spacer (10) from the pulley. Remove spacer (8), seal (12) and bearing (13) from the pulley.Assemble Fan Drive
1. Install bearing (2) in the rear of pulley (3). 2. Put 5P960 Multipurpose Grease on the lip of the seal. Install the lip type seal (1) with tooling (A). The lip of the seal must be away from the bearing.3. Install spacer (5) so the end with the taper is toward the lip type seal.4. Install spacer (6) and bearing (4) in the front of the pulley. 5. Put seal (7) on front of the pulley. Install the pulley on bracket (8).6. Put the washer in position on the bracket shaft and install the bolts that hold the pulley in position on bracket.7. Install the lubrication tube and fill with 5P960 Multipurpose Grease.end by:a) install fan drive