101603-8490 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038490 8943957510

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-8490 1016038490

ISUZU 8943957510 8943957510

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101603-8490 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8490 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6211

3. GOVERNOR 105932-0910

4. SUPPLY PUMP

105210-6080

5. AUTOM. ADVANCE MECHANIS 105672-5250

6. COUPLING PLATE 105661-1140

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7740

11. Nozzle and Holder 8-94393-335-1

12. Open Pre:MPa(Kqf/cm2) 16.2{165}/18.1{185}

13. NOZZLE-HOLDER 105030-4610

14. NOZZLE 105025-0080

15. NOZZLE SET

Include in #1:

101603-8490 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5391 as _

Cross reference number

ZEXEL 101603-8490 1016038490

ISUZU 8943957510 8943957510

Zexel num

Bosch num

Firm num

Name

101603-8490
101603-8491

8943957510 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1-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 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 13

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 86.5 84.9 88.1

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 -

Rack position 9.6+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 86.5 85.5 87.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 95.5 92.3 98.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 77.5 74.3 80.7

Fixing the lever *

Timer adjustment

Pump speed r/min 905--

Advance angle deg. 0 0 0

Load 3/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 855

Advance angle deg. 0.3

Load 3/5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1110

Advance angle deg. 1.5 1 2

Load 3/5

Timer adjustment_05

Pump speed r/min 1450

Advance angle deg. 7 6.5 7.5

Load 5/5

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.
----------
T1=K09
----------

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%
----------

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=R1(13)mm
----------
a=(150deg)

Information:

Make reference to ANALYZING TURBOCHARGER FAILURE, Form No. FEG45138.(1) See TURBOCHARGER IMPELLER INSTALLATION. Do not bend or add stress to the shaft when nut is tightened.(2) Torque for bolts holding thrust plate ... 40 5 lb. in.(4.5 0.6 N m)(3) Tighten bolt holding band clamp to ... 120 10 lb. in.(13.6 1.1 N m)(4) Put 5P3931 Anti-Seize Compound on threads of bolts holding turbine housing and tighten to ... 175 15 lb. in.(19.8 1.7 N m)(5) Put 5P3931 Anti-Seize Compound on threads of bolts holding turbocharger to manifold and tighten to ... 40 4 lb. ft.(55 5 N m)(6) End play for shaft (new) ... .006 to .011 in.(0.15 to 0.27 mm)(7) Bore in the bearing ... .6268 to .6272 in.(15.921 to 15.931 mm) Diameter of surface on shaft (journal) for the bearing ... .6250 to .6254 in.(15.875 to 15.885 mm)(8) Bore in housing ... .9827 to .9832 in.(24.961 to 24.973 mm) Outside diameter of the bearing ... .9780 to .9785 in.(24.841 to 24.854 mm)(9) Clearance between ends of oil seal ring ... .008 to .015 in.(0.20 to 0.38 mm) The radial clearance for the shaft is .004 to .009 in. (0.10 to 0.23 mm).(AiResearch TV81)
(1) Nut for impeller (See TURBOCHARGER IMPELLER INSTALLATION). Do not bend or add stress to the shaft when nut is tightened.(2) Torque for the bolts that hold the backplate ... 90 10 lb. in.(10.2 1.1 N m)(3) Torque for the clamp bolts ... 10 1 lb. ft.(14 1 N m)(4) Bore in the bearings ... .6268 to .6272 in.(15.921 to 15.931 mm) Diameter for the surfaces (journals) on the shaft for the bearings ... .6250 to .6254 in.(15.875 to 15.885 mm)(5) Bore in the housing ... .9827 to .9832 in.(24.961 to 24.973 mm) Outside diameter of the bearings ... .9782 to .9787 in.(24.846 to 24.859 mm)(6) Clearance between the ends of the oil seal ring ... .008 to .015 in.(0.20 to 0.38 mm)(7) End play for the shaft ... .003 to .010 in.(0.08 to 0.25 mm)(8) Torque for support nuts (put 5P3931 Anti-Seize Compound on the stud threads) ... 40 4 lb. ft.(55 5 N m)(AiResearch T18)
Make reference to ANALYZING TURBOCHARGER FAILURE, Form No. FEG45138.(1) End play for shaft ... .0065 .0025 in.(0.165 0.063 mm) Radial clearance for the shaft ... .004 to .009 in.(0.10 to 0.23 mm)(2) Bore in the bearing ... .6268 to .6272 in.(15.921 to 15.931 mm) Diameter of surface on shaft (journal) for the bearing ... .6250 to .6254 in.(15.875 to 15.885 mm)(3) Put 8S6747 Gasket Sealer on bolts holding compressor housing and tighten to ... 105 5 lb. in.(11.9 0.6 N m)(4) Put 5P3931 Anti-Seize Compound on bolts holding turbine housing and tighten to ... 175 15 lb. in.(19.8 1.7 N m)(5) Put 5P3931 Anti-Seize Compound on threads of bolts that hold turbocharger to manifold and tighten to ... 40 4 lb. ft.(55 5 N