101603-8072 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038072 8943938533

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-8072 1016038072

ISUZU 8943938533 8943938533

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Buy INJECTION-PUMP ASSEMBLY 101603-8072 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8072 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6120

3. GOVERNOR 105931-9102

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-0860

6. COUPLING PLATE 105661-1101

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:

101603-8072 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5130 as _

Cross reference number

ZEXEL 101603-8072 1016038072

ISUZU 8943938533 8943938533

Zexel num

Bosch num

Firm num

Name

101603-8072
101603-8073

8943938533 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 26 26

Boost pressure mmHg 195 195

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 26 26

Boost pressure mmHg 195 195

Injection quantity adjustment_05

Adjusting point C

Rack position R1-1.25

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73.6 70.4 76.8

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 R1-1.25

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 12.7 6 19.4

Boost pressure mmHg 95 45 145

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=H66 Ra=12+-0.5mm BCL=1.25+-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=(37deg)+-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)- (5)Pump vertical direction (6)Direction of rotation (7)Pointer (8)Pointer stamping (9)Timing device stamping (10)Timing device (11)Move b deg and stamp both at the same time as shown above. (12)Outside circumference of timing device (13)Secondary timing stamping position for the No. 1 cylinder's beginning of injection
----------
aa=12deg
----------
a=(160deg) b=0deg30min

Information:

2. Remove two short bolts (1) and two longer bolts (2) from manifold (3) and BrakeSaver housing.3. Remove the manifold from the control valve. 4. Remove the three bolts from elbows (5) and the control valve.5. Remove four bolts (4) that hold the control valve to the oil pan.6. Remove the control valve from under the oil pan.7. Make an inspection of the O-ring seals on the manifold and on the control valve. If there is wear or damage make a replacement of the O-ring seals.Install Brakesaver Control Valve
1. Put clean SAE 30 engine oil on O-ring seals (1).2. Put the control valve in position under the oil pan. Install the four bolts that hold the control valve to the oil pan.3. Install the elbow and the bolts that hold it to the side of the control valve. 4. Put SAE 30 engine oil on the O-ring seals of the manifold. Install manifold (2) in the control valve. Install the four bolts that hold the manifold to the BrakeSaver housing.5. Fill the engine with oil. See 3408 TRUCK ENGINE LUBRICATION AND MAINTENANCE GUIDE.Disassemble Brakesaver Control Valve
start by:a) remove BrakeSaver control valve 1. Remove O-ring seals (1) from the valve body.2. Remove four bolts (2) slowly and evenly from cover (4). Remove the cover.
Spring force is behind the cover at removal.
3. Remove cover (3) and the seal from the opposite end of the valve body. 4. Remove spool (8) as an assembly.5. Remove spring (7), stop (10), spring (6) and slug (9).6. Remove the seals and sleeve (5). 7. Remove bolt (11), plate (13) and diaphragm (12) from the spool. Make an inspection of the pin on the spool, and make a replacement of the pin if there is damage or wear.Assemble Brakesaver Control Valve
1. Install diaphragm (4) and plate (8) on valve spool (3). Make alignment of the hole in the plate valve with the pin on the spool. Install the bolt that holds the plate and the diaphragm in position.
When diaphragm (4) is installed on valve spool (3), make sure the fabric side is pulled down over the valve spool to make contact with it and the smooth (rubber coated) side is next to valve body.
2. Install sleeves (1) and the seals in the valve body. 3. Install the valve spool as an assembly into the valve body. As the valve spool is installed, make sure the edge of the diaphragm makes contact all the way around with the groove in the valve body. At this time the valve spool end must extend about 1.50 in. (38.1 mm) from the valve body. Push the valve spool about .25 in. (6.4 mm) - .50 in. (12.7 mm) farther into the valve body until a curved depression is caused between the valve spool and valve body. Make sure there are no wrinkles in the diaphragm. 4. Put cover (9) in position. Install the four bolts that hold the cover on the valve body. Move the valve spool in the