101603-8070 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038070 8943938531

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-8070 1016038070

ISUZU 8943938531 8943938531

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Buy INJECTION-PUMP ASSEMBLY 101603-8070 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8070 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6120

3. GOVERNOR 105931-9100

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-0860

6. COUPLING PLATE 105661-1100

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-7182

11. Nozzle and Holder 8-94394-906-0

12. Open Pre:MPa(Kqf/cm2) 18.1{185}/22.1{225}

13. NOZZLE-HOLDER 105048-3882

14. NOZZLE

15. NOZZLE SET 105019-1020

Include in #1:

101603-8070 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5090 as _

Cross reference number

ZEXEL 101603-8070 1016038070

ISUZU 8943938531 8943938531

Zexel num

Bosch num

Firm num

Name

101603-8070
101603-8071

8943938531 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1-TC2 * 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 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 3.5 3.45 3.55

Rack position
Point A 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 12.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 99.4 97.8 101

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 260 260 260

Average injection quantity mm3/st. 8 6.7 9.3

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(12.6)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 99.4 98.4 100.4

Basic *

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_04

Adjusting point B

Rack position R1(12.6)

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 105.5 102.3 108.7

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_05

Adjusting point C

Rack position R1-1.15

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 76 72.8 79.2

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 102 102 134

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 900 900 900

Rack position R1-1.15

Boost pressure kPa 5.3 4 6.6

Boost pressure mmHg 40 30 50

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Rack position R1(12.6)

Boost pressure kPa 12 5.3 18.7

Boost pressure mmHg 90 40 140

Timer adjustment

Pump speed r/min 1175--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1125

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 3.5 3 4

Load 4/4

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)Adjust so that the boost compensator pushrod protrusion R = Ra at 0 boost. (4)Boost compensator stroke: BCL
----------
T1=G77 Ra=12+-0.5mm BCL=1.15+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=53mm
----------
a=10deg+-5deg b=39deg+-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

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=12deg
----------
a=(160deg)

Information:

start by:a) remove timing gear coverb) remove valve lifters1. Remove the turbocharger drain tube from the flywheel housing. 2. Remove two studs (1) from the flywheel housing. 3. Turn the engine with tool (B). Remove the four bolts from rear camshaft gear (2).
Tooling (A) must be used to prevent the loss of timing of the rear balance weight gear and to keep the rear camshaft gear in place when the camshaft is removed.
4. Install tooling (A) in the flywheel housing. Turn the engine until bolts (3) of tooling (A) engage in the bolt hole of the gear. The two bolts in the rear camshaft gear keep correct timing with the rear balance weight gear.5. Evenly tighten the two bolts (3) to free the gear from the camshaft. 6. Remove two bolts (4) and the thrust plate from front of the engine and camshaft. If necessary, use a driver and hammer to give more impact load on the camshaft gear as follows:a) Loosen tooling (A) to release pressure from the rear camshaft and gear.b) Remove the thrust plate from the front engine block and camshaft.c) Evenly tighten tooling (A) again.d) Use the driver and hammer to free the rear gear from the camshaft taper. 7. Remove camshaft (5) from the front of the engine block.
Be careful not to cause damage to the camshaft bearings.
Install Camshaft
1. Put clean SAE 30 engine oil on the lobes and journals of the camshaft. 2. Install camshaft (1) in the cylinder block with front camshaft gear "V" mark (3) in alignment with the idler and balance weight gear "V" mark. 3. Install thrust plate (2) and the bolts to the front of the engine that hold the camshaft in position. 4. Loosen bolts (5) of tooling (A) from the rear camshaft gear (4) to make alignment of camshaft dowel with the dowel hole in the gear. Install the gear on the camshaft. 5. Install one bolt (6) to hold the gear to the camshaft. Remove tooling (A) from the camshaft gear and flywheel housing.6. Turn the engine with tool (B) and install the remainder of the bolts that hold the gear to the camshaft. Tighten the bolts to a torque of 20 3 lb.ft. (25 4 N m).7. Install the two studs and the turbocharger drain tube to the flywheel housing.end by:a) install valve liftersb) install timing gear cover