101606-0011 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016060011 8943921081


 

Information injection-pump assembly

ZEXEL 101606-0011 1016060011
ISUZU 8943921081 8943921081
101606-0011 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101606-0011 1016060011
ISUZU 8943921081 8943921081


Zexel num
Bosch num
Firm num
Name
101606-0011 
101606-0012 
 
8943921081  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
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

Test data 101606-0011
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

Test data 101606-0011
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=14deg+-5deg b=35deg+-3deg

Stop lever angle

Test data 101606-0011
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-5deg b=40deg+-5deg

0000001501 AIR CYLINDER

Test data 101606-0011
1. (1) Set the speed lever to idle. (2)Screw in air cylinder (A) (3)Set the clearance from the speed lever (B) at approximately L.
----------
L=1mm
----------

Timing setting

Test data 101606-0011
(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:

Using water that meets the minimum acceptable water requirement may not prevent drop-out of these chemical compounds totally, but should minimize the rate to acceptable levels.To determine water characteristics, contact local water department, agricultural agent or an independent laboratory to perform the testing service. Two companies are listed below. However, there are others who are qualified to provide this service.L.O.C.C. Corp.
905 Bayshore Drive
Coos Bay, OR 97420
Ph. (503) 267-4904
NALCO Chemical Co.
Naperville Technical Center
One Nalco Center
Naperville, IL 60566
Attn: Sample Receiving
Ph. (312) 961-9500
Antifreeze
Caterpillar recommends that the coolant mix contain a minimum of 30% Caterpillar Antifreeze, or equivalent and acceptable water to maintain an adequate water pump cavitation temperature for efficient water pump performance.
Premix coolant solution to provide protection to the lowest expected outside (ambient) temperature. Pure undiluted antifreeze will freeze at- 10°F (-23°C).Only use a greater concentration (above 30%) of Caterpillar Antifreeze as needed for anticipated outside (ambient) temperatures. Do not exceed a coolant mixture of 60% antifreeze to water since a concentration above 60% antifreeze will reduce the engine's freeze protection and increase the possibility of deposit formation in the cooling system.Use Caterpillar Antifreeze or ASTM D4985-89 (GM Specification 6038-M) Antifreeze. Caterpillar Antifreeze is available through your Caterpillar dealer in quantities that follow. Most commercial antifreezes are formulated for gasoline engine applications and will, therefore, have high silicate content. Caterpillar Antifreeze is formulated with a low silicate content and the proper coolant additives for heavy duty diesel engines.ASTM D4985-89 (GM Specification 6038-M) is a low silicate antifreeze, but supplemental coolant additive must be added.The major advantages of Caterpillar Antifreeze are: * Significantly reduces water pump seal leakage problems caused by excessive concentration of chemical additives.* There is no need to add supplemental coolant additive on initial fill which must be done with current commercially available antifreezes.* High silicate antifreezes used with a supplemental coolant additive can cause a build-up of solids over a period of time which can cause plugging, loss of heat transfer, and water pump seal damage. Make proper antifreeze additions.Adding pure antifreeze as a makeup solution for cooling system top-up is an unacceptable practice. It increases the concentration of antifreeze in the cooling system which increases the concentration of dissolved solids and undissolved chemical inhibitors in the cooling system. Add antifreeze mixed with water to the same freeze protection as your cooling system.Use the chart below to assist in determining the concentration of Caterpillar Antifreeze to use.
5P0957 Coolant Tester (°F) or 5P3514 Coolant Tester (°C)Both are available at your Caterpillar dealer.Check the coolant solution frequently in cold weather for glycol concentration with the 5P0957 or 5P3514 Coolant Tester to ensure adequate protection. Both testers are identical except temperature scale. They give immediate, accurate readings and can be used for antifreeze/coolants that contain ethylene or propylene glycol.If propylene glycol based antifreeze is used, DO NOT allow concentration greater than a 50/50 antifreeze to water mixture. The measurement of freeze protection must be made with a refractive-type tester (Cat 5P0957 or 5P3514) rather than a hydrometer-type, which can be

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