101603-8140 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038140 8943943140

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-8140 1016038140

ISUZU 8943943140 8943943140

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Service parts 101603-8140 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6080

3. GOVERNOR 105931-8831

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-0820

6. COUPLING PLATE 105661-0840

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5702

11. Nozzle and Holder 8-94394-787-1

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

13. NOZZLE-HOLDER 105048-3862

14. NOZZLE

105017-1090

15. NOZZLE SET

Include in #1:

101491-0610 as _

101603-8140 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-8140 1016038140

ISUZU 8943943140 8943943140

Zexel num

Bosch num

Firm num

Name

101603-8140
101603-8141

8943943140 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1-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 3.6 3.55 3.65

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 11.3

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 75.7 74.1 77.3

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. 8.8 7.5 10.1

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(11.3)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 75.7 74.7 76.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 87.3 83.3 91.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(11.3)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 61.8 58.6 65

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 96 96 104

Fixing the lever *

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=G95
----------

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=11deg+-5deg b=40deg+-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

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:

(1) 7S7144 Spring for valves (new): Length under test force ... 1.766 in.(44.86 mm)Test force ... 57.7 4.5 lb.(257 20 N)Use again minimum load at length under test force ... 46.5 lb.(207 N)Length of spring at valve open position ... 1.271 in.(32.28 mm)Use again minimum load at valve open position ... 144 lb.(640 N)Free length after test ... 2.05 in.(52.1 mm)Outside diameter ... 1.386 in.(35.20 mm)Spring must not be bent more than ... .072 in.(1.83 mm)(2) Height to top of valve guide ... .875 in.(22.23 mm)(3) Diameter of valve stem (new) ... .3717 .0003 in.(9.441 0.008 mm) Use again minimum diameter ... .3704 in.(9.408 mm)Bore in valve guide with guide installed in the head (new) ... .3733 .0010 in.(9.482 0.025 mm)Maximum permissible bore (worn) ... .3771 in.(9.578 mm)(4) Valve lip thickness: 8N875 Exhaust ValveUse again minimum ... .106 in.(2.69 mm)7S8809 Intake ValveUse again minimum ... .106 in.(2.69 mm)(5) Diameter of valve head: Exhaust valve ... 1.896 .005 in.(48.16 0.13 mm)Intake valve ... 2.020 .005 in.(51.31 0.13 mm)(6) Angle of valve face ... 291/4° (7) Depth of bore in head for valve seat insert: Exhaust (5S7221) ... .449 .005 in.(11.40 0.13 mm)Intake Earlier (5S7218) ... .449 .005 in.(11.40 0.13 mm)Later (7N4448) ... .349 .005 in.(8.86 0.13 mm)(8) Diameter of valve seat insert: Exhaust (5S7221) ... 2.0035 .0005 in.(50.889 0.013 mm)Intake Earlier (5S7218) ... 2.1285 .0005 in.(54.064 0.013 mm)Later (7N4448) ... 2.0485 .0005 in.(52.032 0.013 mm)Bore in head for valve seat insert:Exhaust (5S7221) ... 2.0005 .0005 in.(50.813 0.013 mm)Intake Earlier (5S7218) ... 2.1255 .0005 in.(53.988 0.013 mm)Later (7N4448) ... 2.0457 .0005 in.(51.961 0.013 mm)(9) Angle of face of valve seat insert ... 30°(10) Maximum permissible width of valve seat (intake and exhaust) ... .076 in.(1.93 mm) Minimum permissible width of valve seat (intake and exhaust) ... .045 in.(1.14 mm)(11) Dimension from top of closed valve to face of head: Maximum permissible dimension for 8N875 Exhaust Valve ... .163 in.(4.14 mm)Minimum permissible dimension for 8N875 Exhaust Valve ... .079 in.(2.01 mm)Maximum permissible dimension for 7S8809 Intake Valve ... .140 in.(3.56 mm)Minimum permissible dimension for 7S8809 Intake Valve ... .066 in.(1.68 mm)(12) Outside diameter of the face of the valve seat or valve seat insert: Exhaust seat ... 1.810 in.(45.97 mm)Maximum permissible exhaust seat ... 1.860 in.(47.24 mm)Intake seat ... 1.934 in.(49.12 mm)Maximum permissible, intake seat ... 1.984 in.(50.39 mm)(13) Angle to grind seat face of the insert to get a reduction of maximum seat diameter ... 15°