101603-8672 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016038672 8943959682

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-8672 1016038672

ISUZU 8943959682 8943959682

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Cross reference number

ZEXEL 101603-8672 1016038672

ISUZU 8943959682 8943959682

Zexel num

Bosch num

Firm num

Name

101603-8672
101603-8673

8943959682 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 18

Opening pressure kgf/cm2 184

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.95 4.05

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 11.6

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 91.5 89.9 93.1

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 Z

Rack position 9.6+-0.5

Pump speed r/min 240 240 240

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 *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 91.5 90.5 92.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.95

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 100.5 96.5 104.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.6

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 98.5 94.5 102.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 130 130 138

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 905--

Advance angle deg. 0 0 0

Load 0/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 855

Advance angle deg. 0.3

Load 0/4

Timer adjustment_03

Pump speed r/min (900)

Advance angle deg. 0 0 0

Load 4/4

Remarks
Start

Timer adjustment_04

Pump speed r/min 1425

Advance angle deg. 5.5 5 6

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)RACK LIMIT
----------
T1=K97
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=13deg+-5deg b=38deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-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=7deg
----------
a=(150deg)

Information:

Remove Timing Gears And Plate
start by:a) remove timing gear coverb) remove fuel injection pump and governor drive 1. Remove four bolts (2), plate (3) and idler gear (1).2. Use tooling (A) to remove camshaft gear (4).
Do not turn the crankshaft with camshaft gear removed. Damage can be caused to pistons and valves or both.
3. Remove bolts (5) that hold timing gear plate (6) to cylinder block.4. Remove timing gear plate (6). 5. Use tooling (B) to remove the bearing from the idler gear.Install Timing Gears And Plate
1. Install a new gasket on timing gear plate. 2. Put timing gear plate (1) in position on cylinder block and install the bolts that hold timing gear plate to cylinder block.4. Heat camshaft gear (2) to a maximum temperature of 600°F (315°C) and install it on the camshaft. 5. Use tooling (A) and install the bearing in the idler gear. Install the bearing to a depth of .06 .02 in. (1.5 0.5 mm) below the rear face of the idler gear.6. Install idler gear, plate and bolts. Be sure No. 1 cylinder is at top center on compression stroke. Install idler gear so the "V" mark (4) on idler gear is in alignment with "V" mark on crankshaft gear. The "K" marks (3) of camshaft gear can be seen at outer edges of idler gear.end by:a) install fuel injection pump and governor driveb) install timing gear cover