101603-7310 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037310 1156025850

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-7310 1016037310

ISUZU 1156025850 1156025850

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Service parts 101603-7310 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4211

3. GOVERNOR 105492-0310

4. SUPPLY PUMP 105210-4730

5. AUTOM. ADVANCE MECHANIS 105644-0430

6. COUPLING PLATE 105662-0630

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5452

11. Nozzle and Holder 1-15300-107-2

12. Open Pre:MPa(Kqf/cm2) 17.2{175}

13. NOZZLE-HOLDER 105031-3782

14. NOZZLE 105015-4840

15. NOZZLE SET

Include in #1:

101481-0154 as _

101603-7310 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-7310 1016037310

ISUZU 1156025850 1156025850

Zexel num

Bosch num

Firm num

Name

101603-7310

1156025850 ISUZU

INJECTION-PUMP ASSEMBLY
6QA1 * K 14BF PE6AD PE

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 131424-0220

Overflow valve opening pressure kPa 147 113 181

Overflow valve opening pressure kgf/cm2 1.5 1.15 1.85

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.7 3.65 3.75

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 8.9

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 71 69 73

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 69.9 68.9 70.9

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8 5.7 10.3

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 500

Advance angle deg. 0.3

Remarks
Start

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 0.8 0.1 0.8

Timer adjustment_03

Pump speed r/min 700

Advance angle deg. 0.8 0.3 1.3

Timer adjustment_04

Pump speed r/min 900

Advance angle deg. 2 1.5 2.5

Timer adjustment_05

Pump speed r/min 1150

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)RACK LIMIT: RAL (4)Damper spring setting: DL
----------
RT=1 TH=2.7mm RAL=13.8+0.2mm DL=6.5+-0.5mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=8deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=18deg+-3deg b=30deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=65.5deg+-5deg b=71deg+-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=17deg
----------
a=(60deg)

Information:

Image1.1.1
4) Remove the 90 degree pressure line fitting under the sensor box.
5) Remove the 90 degree pressure line fitting from the DPF center section that is closest to the outlet side.
6) The new pressure line that will fit into the DPF center section will need to be installed into the port in which the thermocouple was fitted. The existing thermocouple will need to be fitted into the port in which the old pressure line was fitted.
Swapping of the ports is only necessary on the outlet side of the center section.
Image1.2.1
Image1.2.2
7) Install the 7W-3556 washer on the 304-8042 straight fitting. Install the straight fitting into the DPF pressure port (towards the outlet side) in which the thermocouple was previously installed, tighten to a torque of 24 +/- 4 Nm (212 +/- 35 lb-in). Screw the 2N-8142 tee fitting onto that straight fitting and tighten to a torque of 24 +/- 4 Nm (212 +/- 35 lb-in).
Image1.3.1
8) Replace the O-ring on the sensor box where the old 90 degree pressure line fitting was located. Install the 4S-4857 tee fitting in the sensor box to a torque of 11 +/- 1 Nm (97 +/- 9 lb-in).
Image1.4.1
9) Where applicable, perform Service Letter REBE3391 at this time.
10) Install sensor box bracket and existing heat shield. Tighten all six bolts to a torque of 12 +/- 3 Nm (106 +/- 27 lb-in).
11) Install sensor box, new pressure lines (tube assemblies), thermocouples onto DPF, and cable straps.
Reference appropriate Disassembly and Assembly manual for proper torque and use of anti-seize.
Image1.5.1
12) Start the engine and use CAT ET to ensure that the status parameter Diesel Particulate Trap #1 Differential Pressure has a value greater than zero. Also, ensure status parameters Diesel Particulate Trap #1 Intake Temperature, and Diesel Particulate Trap #1 Outlet Temperature show reasonable values and increase with the rising exhaust temperatures.