101603-7425 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037425 8943968753

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-7425 1016037425

ISUZU 8943968753 8943968753

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Service parts 101603-7425 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4960

3. GOVERNOR 105931-7592

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-0620

6. COUPLING PLATE 105661-0781

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5084

11. Nozzle and Holder 8-94397-483-2

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

13. NOZZLE-HOLDER 105048-3862

14. NOZZLE

105017-1090

15. NOZZLE SET

Include in #1:

101603-7425 as INJECTION-PUMP ASSEMBLY

Include in #2:

104742-1311 as _

Cross reference number

ZEXEL 101603-7425 1016037425

ISUZU 8943968753 8943968753

Zexel num

Bosch num

Firm num

Name

101603-7425
101603-7426

8943968753 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1-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 105780-8210

Nozzle 105780-0070

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 4.2 4.15 4.25

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 11.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73.5 71.9 75.1

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 H

Rack position 9.5+-0.5

Pump speed r/min 260 260 260

Average injection quantity mm3/st. 8.3 7 9.6

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(11.2)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73.5 72.5 74.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 84.6 80.6 88.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.3

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 55.3 52.1 58.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 103 103 135

Fixing the lever *

Timer adjustment

Pump speed r/min 1210--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1160

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1500

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.
----------
T1=G22
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=11deg+-5deg b=(39deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=62.5mm
----------
a=12.5deg+-5deg b=29deg+-5deg

0000001501 AIR CYLINDER

1. (1) Set the speed lever to idle. (2)Screw in air cylinder (A) (3)Set the clearance from the speed lever (B) at approximately L.
----------
L=1mm
----------

0000001601 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=131153-4520 ST=A724 L1=1mm L2=4.2+-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)- (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=11deg
----------
a=(150deg) b=1deg

Information:

2. Remove the two bolts (1) from transfer pump, and pull the pump out of accessory drive housing.3. Remove the four bolts and lock from retainer (3). Remove the retainer.4. Remove the drive gear (2). 5. Remove the two bolts, locks, and plate (5).6. Remove the variable timing unit (4) from the accessory drive housing.Install Variable Timing Unit
1. Put the variable timing unit (1) in position in the accessory drive housing.2. Install the retaining plate, locks, and two bolts.3. Install the drive gear, retainer, lock, and four bolts. Do not tighten the four bolts.4. Make an adjustment to the timing of the camshaft for the fuel injection pump. See FUEL INJECTION PUMP CAMSHAFT TIMING in TESTING AND ADJUSTING. 5. Install the cover (4) on timing gear housing.6. Put the transfer pump (3) in position on the accessory drive housing, and install the two bolts (2).7. Check to be sure all timing pins and bolts have been removed from their timing holes, and are installed in their storage positions.Disassemble Variable Timing Unit
start by: a) remove variable timing unit 1. Push down on retainer (1), and remove the pin (2).2. Remove the retainer and spring. 3. Use a hammer and punch to remove the dowels (4). Remove the two weights.4. Remove the piston and rod assembly (5) from shaft assembly (3).5. Remove the pins from nut and rod.6. Remove the rod, nut, spring, and valve from the piston assembly.Assemble Variable Timing Unit
1. Install the valve, spring, and nut on the piston assembly. Turn the nut until the distance (X) between bottom face of nut and the piston is 1.760 in. (44.7 mm). Drill a .095 .002 in. (2.41 0.05 mm) diameter hole through the nut and the threads of piston assembly. Install the pin in nut. 1. Install the rod tight against the nut. Take a measurement .156 in. (3.96 mm) from top face of nut, and put a mark at this location on rod. Drill a .095 .0.05 mm) diameter hole (1) through the rod and piston assembly at this location. Install the pin in rod.3. Install the piston and rod assembly in the shaft assembly. Install the spring, retainer, and pin in shaft assembly.4. Install the weights and dowels. Use a hammer and punch to fasten both ends of the dowels in place. Both weights must move freely after the dowels have been fastened in place.end by: a) install variable timing unit