101603-8861 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038861 8943909611

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-8861 1016038861

ISUZU 8943909611 8943909611

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Cross reference number

ZEXEL 101603-8861 1016038861

ISUZU 8943909611 8943909611

Zexel num

Bosch num

Firm num

Name

101603-8861
101603-8862

8943909611 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1 * 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 4.2 4.15 4.25

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 10.9

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 71 69.4 72.6

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 -

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(10.9)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 71 70 72

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.45

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 87.5 83.5 91.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(10.9)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 57 53.8 60.2

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 125 125 133

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=K77
----------

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=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-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=(160deg)

Information:

REMOVING COVER
1. Cover.3. Remove screw (2) from rack stop collar (3).
REMOVING SCREW
2. Screw. 3. Rack stop collar.
REMOVING RACK STOP COLLAR
3. Rack stop collar. 4. Spring. 5. Collar.4. Remove rack stop collar (3), spring (4), and collar (5).5. Remove high idle screw (7), bolts (6), and the torque spring. Use wire to fasten the torque spring components together.
HIGH IDLE SCREW
6. Bolts (two). 7. High idle screw.6. Remove the governor housing-to-adapter assembly retaining bolts (8).
GOVERNOR HOUSING RETAINING BOLTS
8. Retaining bolts.
GOVERNOR HOUSING
9. Governor housing. 10. High idle spring.7. Remove governor housing (9) and high idle spring (10).8. Remove the governor spring assembly (11).
REMOVING GOVERNOR SPRING ASSEMBLY
11. Governor spring assembly.9. Remove the bolts (12) and lock (14) from the cylinder and weight assembly (13).
CYLINDER AND WEIGHT ASSEMBLY
12. Bolts. 13. Cylinder and weight assembly. 14. Lock.10. Remove the cylinder and weight assembly (13).
REMOVING CYLINDER AND WEIGHT ASSEMBLY
13. Cylinder and weight assembly.11. Remove piston (15) and spring (16).
REMOVING PISTON
15. Piston. 16. Spring. 17. Bolts.12. Remove the adapter assembly retaining bolts (17) and remove adapter assembly (18) from the fuel injection pump housing.
REMOVING ADAPTER ASSEMBLY
18. Adapter assembly.13. Remove adapter (19) from adapter assembly (18).
REMOVING ADAPTER
18. Adapter assembly. 19. Adapter.Install Governor
1. Put adapter (19) in adapter assembly (18).
INSTALLING ADAPTER
18. Adapter assembly. 19. Adapter.2. Position adapter assembly (18) on fuel injection pump housing so slot in adapter (19) is engaged with groove in rack (20).
INSTALLING ADAPTER ASSEMBLY
18. Adapter assembly. 20. Rack.
INSTALLING PISTON
15. Piston. 16. Spring.3. Install spring (16) and piston (15) in adapter assembly (18).4. Position cylinder and weight assembly (13) on adapter assembly (18) so slot in the piston is engaged with groove in adapter (19).
POSITIONING CYLINDER AND WEIGHT ASSEMBLY
13. Cylinder and weight assembly. 18. Adapter assembly. 19. Adapter.5. Install bolts (12) and lock (14) that hold cylinder and weight assembly (13).
INSTALLING CYLINDER AND WEIGHT ASSEMBLY
12. Bolts. 13. Cylinder and weight assembly. 14. Lock.
INSTALLING GOVERNOR SPRING ASSEMBLY
11. Governor spring assembly.6. Install governor spring assembly (11).7. Install governor high idle spring (10). Position governor housing (9) on the adapter assembly.
INSTALLING GOVERNOR HIGH IDLE SPRING
9. Governor housing. 10. High idle spring.8. Install bolts (8) that hold the governor housing to the adapter assembly.
BOLTS INSTALLED
8. Bolts.
TORQUE SPRING INSTALLED
6. Bolts. 7. High idle screw.9. Install high idle screw (7). Install the torque spring and bolts (6).10. Install spring (4), collar (5), and rack stop collar (3).
INSTALLING RACK STOP COLLAR
3. Rack stop collar. 4. Spring. 5. Collar.11. Install the rack stop collar retaining screw (2).
INSTALLING SCREW
2. Screw. 3. Rack stop collar.
INSTALLING COVER
1. Cover.12. Install the fuel injection pump housing and governor on the engine as a unit. Set the rack and adjust the governor. See the topics FUEL RACK SETTING and GOVERNOR ADJUSTMENTS in TESTING AND ADJUSTING section of the Service Manual.13. Install cover (1) on the rear of the governor.