101603-8350 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038350 8943953270

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-8350 1016038350

ISUZU 8943953270 8943953270

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Cross reference number

ZEXEL 101603-8350 1016038350

ISUZU 8943953270 8943953270

Zexel num

Bosch num

Firm num

Name

101603-8350
101603-8351

8943953270 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 12.9

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 84 82.4 85.6

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(12.9)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 84 83 85

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 94.5 91.3 97.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 75 71.8 78.2

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 -

Advance angle deg. 1.5 1 2

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1110

Advance angle deg. 1.5 1 2

Load 3/5

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. (3)At delivery (at R = RA, N = N1)
----------
T1=J58 RA=R1(12.9)mm N1=150r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)Set the idle side stopper bolt at rack position = bb (at shipping).
----------
aa=43mm bb=R1(12.9)mm
----------
a=5deg+-5deg b=39deg+-3deg c=(9deg)

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=131153-9020 ST=A769 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)-
----------
aa=6deg
----------
a=(150deg)

Information:

3. Remove connecting rod caps (1) from the two connecting rods and push the pistons up until the rings are free of the cylinder liner.4. Remove the two pistons.5. Do the above steps again for the remainder of the pistons.Install Pistons
1. Turn the crankshaft until the bearing journals for the pistons to be installed are at bottom center.2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and connecting rod bearings.3. Move the piston rings on the piston until the ring openings (gap) are approximately 180° apart.
Never install tool (A) (the ring compressor) without the use of the cylinder liner as a guide. Damage to the piston rings can be the result.
TYPICAL EXAMPLE4. Put tool (A) in position on the cylinder liner as shown. Put the connecting rod and piston in position in the same cylinder liner from which it was removed and into the ring compressor. Make sure the "V" mark on the piston is in alignment with the "V" mark on the cylinder block.5. Push the piston into position while the connecting rod is put into position over the crankshaft. 6. Put clean engine oil on bearings, bolt threads and surfaces of the nuts that make contact with the connecting rod caps. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 30 3 lb.ft. (40 4 N m). Put a mark on each nut and the end of each bolt. Tighten the nuts 90° more.
When the connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
7. Follow Steps 1 through 6 for the installation of the other pistons.end by:a) install oil pumpb) install cylinder head assemblyDisassemble And Assemble Pistons
start by:a) remove pistons 1. Remove keystone rings from the piston with tool (A). 2. Remove snap ring (3), piston pin (1) and connecting rod (2) from the piston.3. Clean the piston ring grooves on the old piston with an acceptable ring groove tool. For clearances on pistons and rings of earlier models, see PISTON AND RINGS in SPECIFICATIONS.4. See SPECIAL INSTRUCTIONS, Form SMHS7295 for USE OF PISTON PIN REMOVAL AND INSTALLATION TOOLS. Be sure to remove the bearings from the crankshaft end of connecting rod.5. Heat the connecting rod in an oven to a temperature of 350°-500°F (176°-260°C). Never use a direct flame to heat a connecting rod. 6. Put the connecting rod in position on tooling (B) for the regular rod. Use tooling (C) for the tapered rod. Put a new rod pin bearing in position. Make sure the rod pin bearing joint (4) is 90° from a center line through crankshaft and pin bearing bores.7. Remove the old rod pin bearing and install the new rod pin bearing with one operation. 8. Use a pin bearing machine