101603-8051 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038051 1156027591

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-8051 1016038051

ISUZU 1156027591 1156027591

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Buy INJECTION-PUMP ASSEMBLY 101603-8051 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8051 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3880

3. GOVERNOR 105921-5840

4. SUPPLY PUMP 105210-5100

5. AUTOM. ADVANCE MECHANIS 105643-0850

6. COUPLING PLATE 105662-1170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6653

11. Nozzle and Holder 1-15300-288-3

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105015-9031

15. NOZZLE SET

Include in #1:

101603-8051 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-5170 as _

Cross reference number

ZEXEL 101603-8051 1016038051

ISUZU 1156027591 1156027591

Zexel num

Bosch num

Firm num

Name

101603-8051

1156027591 ISUZU

INJECTION-PUMP ASSEMBLY
6SA1 * K 14BF PE6AD PE

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 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.7 3.65 3.75

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 700 700 700

Average injection quantity mm3/st. 73.9 72.3 75.5

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 300 300 300

Average injection quantity mm3/st. 9 7.7 10.3

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 700 700 700

Average injection quantity mm3/st. 73.9 72.9 74.9

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(11.3)

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 86.4 82.4 90.4

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 103 103 113

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 990

Advance angle deg. 3.5 3 4

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=G72
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=19deg+-5deg b=38deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-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=16deg
----------
a=(40deg)

Information:

start by: a) remove flywheelb) remove electric starting motorc) remove air compressord) remove turbochargere) remove oil pan 1. Remove the bolts from collar (2) and elbow (1).2. Remove the bolts from support (3). Remove bolts (4) from behind the support.3. Remove the exhaust manifold and support. Remove O-ring seal (5) from between the support and flywheel housing. 4. Fasten tooling (A) and a hoist to the flywheel housing (6). Remove the bolts that hold the flywheel housing in position. Remove the flywheel housing. Weight of the housing is 80 lb. (36 kg).
Do not cause damage to the crankshaft rear seal when the flywheel housing is removed.
Install Flywheel Housing
1. Install a new gasket on the rear of the engine block. 2. Put clean SAE 30 engine oil on the crankshaft rear seal wear sleeve and on the rear seal (2).3. Fasten a hoist and tooling (A) to flywheel housing (1). Put the flywheel housing in position on the engine block.
Be careful not to cause damage to the rear seal.
4. Install the bolts that hold the flywheel housing to the cylinder block. 5. Remove tooling (A). Install O-ring seal (5) on the oil (supply) hole in the flywheel housing and between the support.6. Put exhaust manifold and support (6) in position on the flywheel housing.7. Put 9M3710 Anti-Seize Compound on the bolts that hold the exhaust manifold and support. Install the bolts in the support.8. Install the gaskets between exhaust manifold collar (4) and at the elbow (3). Install the bolts and nuts that hold the manifolds together.end by: a) install oil panb) install turbochargerc) install air compressord) install electric startere) install flywheel