Information injection-pump assembly
ZEXEL
101603-8220
1016038220
ISUZU
8943949140
8943949140
Rating:
Cross reference number
ZEXEL
101603-8220
1016038220
ISUZU
8943949140
8943949140
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
4.2
4.15
4.25
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
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.
69
67.4
70.6
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
9.8+-0.5
Pump speed
r/min
265
265
265
Average injection quantity
mm3/st.
18.2
16.9
19.5
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.
69
68
70
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
103
103
135
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1210--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1160
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
5.5
5
6
Load
4/4
Remarks
Finish
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.
----------
T1=G16
----------
----------
T1=G16
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=12.5deg+-5deg b=(45deg)+-3deg
----------
aa=36mm
----------
a=12.5deg+-5deg b=(45deg)+-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
----------
aa=45mm
----------
a=12.5deg+-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=131153-4520 ST=A724 L1=1mm L2=4.2+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131153-4520 ST=A724 L1=1mm L2=4.2+-0.05mm a1=+-14% a2=+-2.5%
----------
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)-
(5)Pump vertical direction
(6)Direction of rotation
(7)Pointer
(8)Pointer stamping
(9)Timing device stamping
(10)Timing device
(11)Stamp both at the same time as shown above.
(12)Outside circumference of timing device
(13)Secondary timing stamping position for the No. 1 cylinder's beginning of injection
----------
aa=11deg bb=1deg
----------
a=(150deg)
----------
aa=11deg bb=1deg
----------
a=(150deg)
Information:
1. Preparation of vehicle for fuel consumption test (consult dynamometer manufacturer's operating instructions for specific details on correct operation). Always perform the Primary Engine Test procedure before vehicle is installed on chassis dynamometer.a. Place vehicle on the chassis dynamometer. Tie the vehicle in a way that will not add any load to the drive wheels. Do not pull wheels down into dynamometer drive rolls. Check the radiator coolant level, crankcase oil level, tire pressure, tire condition, remove rocks from the tire tread and connect exhaust system.
Recapped tires should be run on a chassis dynamometer only at the customer's own risk.
b. The maximum acceptable fuel rate must be calculated for the customer's engine by use of the formula that follows: Find the rated brake specific fuel consumption (lb-bhp/hr) from the RACK SETTING INFORMATION and add .010 in. manufacturing tolerance. Multiply this value by the advertised engine horsepower (plus 3% manf. tol.) and divide by the density of the fuel (lbs/gal).c. Calculate the allowable limits that the customer can expect from his engine and present these figures to him. Caterpillar engines are rated with the conditions that follow: Measure and record these variables. Advertised engine bhp (less 3% manufacturing tolerance) can then be corrected to test conditions by use of procedure and correction tables found in Special Instruction GEG01024.2. Operate vehicle at 60% of rated speed with moderate load until oil and coolant temperatures reach their normal range for operation.
If there is a heavy vibration, drive shaft whip, tire bounce, etc., do not continue with dynamometer test until cause of the problem is corrected. Engines that have had new internal parts installed should be operated on a run-in schedule before operation at full load.
Put transmission in direct gear and the differential in the highest speed ratio. Operate vehicle at maximum engine speed and increase chassis dynamometer load until a speed of 50 rpm less than rated speed is reached (continuity light should be on). Maintain this speed for one minute and record the engine speed, wheel horsepower and fuel rate.3. If the fuel rate and the wheel horsepower are both acceptable, then the engine is not the cause of the complaint, or the complaint is not valid. Refer to section PROBLEM WITH VEHICLE OR VEHICLE OPERATION.4. If the
Recapped tires should be run on a chassis dynamometer only at the customer's own risk.
b. The maximum acceptable fuel rate must be calculated for the customer's engine by use of the formula that follows: Find the rated brake specific fuel consumption (lb-bhp/hr) from the RACK SETTING INFORMATION and add .010 in. manufacturing tolerance. Multiply this value by the advertised engine horsepower (plus 3% manf. tol.) and divide by the density of the fuel (lbs/gal).c. Calculate the allowable limits that the customer can expect from his engine and present these figures to him. Caterpillar engines are rated with the conditions that follow: Measure and record these variables. Advertised engine bhp (less 3% manufacturing tolerance) can then be corrected to test conditions by use of procedure and correction tables found in Special Instruction GEG01024.2. Operate vehicle at 60% of rated speed with moderate load until oil and coolant temperatures reach their normal range for operation.
If there is a heavy vibration, drive shaft whip, tire bounce, etc., do not continue with dynamometer test until cause of the problem is corrected. Engines that have had new internal parts installed should be operated on a run-in schedule before operation at full load.
Put transmission in direct gear and the differential in the highest speed ratio. Operate vehicle at maximum engine speed and increase chassis dynamometer load until a speed of 50 rpm less than rated speed is reached (continuity light should be on). Maintain this speed for one minute and record the engine speed, wheel horsepower and fuel rate.3. If the fuel rate and the wheel horsepower are both acceptable, then the engine is not the cause of the complaint, or the complaint is not valid. Refer to section PROBLEM WITH VEHICLE OR VEHICLE OPERATION.4. If the