101603-8342 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038342 8943953153

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-8342 1016038342

ISUZU 8943953153 8943953153

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Service parts 101603-8342 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6350

3. GOVERNOR 105932-0532

4. SUPPLY PUMP

105210-6080

5. AUTOM. ADVANCE MECHANIS 105672-5250

6. COUPLING PLATE 105661-1140

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7740

11. Nozzle and Holder 8-94393-335-1

12. Open Pre:MPa(Kqf/cm2) 16.2{165}/18.1{185}

13. NOZZLE-HOLDER 105030-4610

14. NOZZLE 105025-0080

15. NOZZLE SET

Include in #1:

101401-4292 as _

101603-8342 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-8342 1016038342

ISUZU 8943953153 8943953153

Zexel num

Bosch num

Firm num

Name

101603-8342
101603-8343

8943953153 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1-S * 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 4.7 4.65 4.75

Rack position
After adjusting injection quantity. 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 12.1

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 83 81.4 84.6

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 H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

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(12.1)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 83 82 84

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 95 91.8 98.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.15

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 70 66.8 73.2

Fixing the lever *

Timer adjustment

Pump speed r/min 905--

Advance angle deg. 0 0 0

Load 3/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 855

Advance angle deg. 0.3

Load 3/5

Timer adjustment_03

Pump speed r/min 1110

Advance angle deg. 1.5 1 2

Load 3/5

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_05

Pump speed r/min 1450

Advance angle deg. 7 6.5 7.5

Load 5/5

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.
----------
T1=K86
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=33mm
----------
a=11deg+-5deg b=47deg+-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

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131150-0420 ST=A792 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------

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)At rack position = bb
----------
aa=6deg bb=12.1mm
----------
a=(150deg)

Information:

start by:a) remove turbocharger 1. Put the turbocharger in position on tool (A). Move tool (A) so the compressor housing is up. 2. For installation alignment purposes, make a mark on the center housing and turbine housing. Bend down the lock plates and remove six bolts (1). If some of the bolts are hard to remove, put penetrating oil on the bolt and hit the flat of the bolt head with a punch and hammer. 3. Lift the center housing and turbine wheel out of the turbine housing. If the assembly is hard to get apart, lift up on the compressor housing and hit the turbine housing with a soft hammer. 4. Remove clamp (2) from the compressor housing. For installation alignment purposes, make a mark on the center housing and the compressor housing. 5. Lift the center housing out of the compressor housing. Put the turbine wheel in tooling (B).6. Remove nut (3) with a universal socket. Remove O-ring (4).
Do not put a side force on the shaft when the nut is removed.
7. Heat the compressor wheel in oil for no more than ten minutes. The temperature of the oil must be 350° 25°F (176° 14°C).
The bearing heating oil used to heat the compressor wheel must have a flash point above 400°F (204°C).
8. Immediately after removing the compressor wheel from the oil, put the center housing in a press and use tooling (C) and (D) to remove the compressor wheel and center housing from the shaft.
Do not let the turbine wheel hit the bottom of the press.
9. Put the turbine wheel in tooling (B) and remove ring (6) and shroud (5). 10. Remove three bolts (7) and the three lock plates from center housing (8). 11. Remove plate (9) with tool (E). Remove the O-ring from plate (9). 12. Remove spacer (10) from plate (9). Remove collar (11) and thrust bearing (15). Remove bearing (12) and put a long dye mark on the top face of the bearing. Use tool (F) to remove rings (16) and (13). Remove bearing (17) and put a short dye mark on the top face of the bearing. Remove ring (14) with tool (F). The dye marks are for identification when installing the bearings.13. Inspect all parts and install new parts if needed. Use Special Instruction Form No. GMG00153-01, Turbocharger Reconditioning, Form No. FEG45138, Analyzing Turbocharger Failure and Video Tape JEG08054 (1/2 inch reel) (JEG09052-cassette), Turbocharger Reconditioning I (AIRESEARCH) for references.Assemble Turbocharger
1. Make sure all oil passages are open and clean. Put clean engine oil on all parts before assembly. 2. Install ring (3) with tool (A). Install bearing (4) with the short dye mark up. Install rings (2) and (1) with tool (A). Rings (1), (2) and (3) must be installed with the round edge toward the bearing. 3. Install shroud (5) on the turbine shaft. Install ring (6). Put 6V2055 High Vacuum Grease on ring (6) and fill the groove for the ring to one half depth all