101603-7520 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037520 8943969220

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-7520 1016037520

ISUZU 8943969220 8943969220

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Service parts 101603-7520 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4960

3. GOVERNOR 105931-7601

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-0720

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:

101603-7520 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-6730 as _

Cross reference number

ZEXEL 101603-7520 1016037520

ISUZU 8943969220 8943969220

Zexel num

Bosch num

Firm num

Name

101603-7520
101603-7521

8943969220 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

Bosch type code DN12SD12T-1

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 1270--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1220

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 5.5 5 6

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=F10
----------

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=(36.5deg)+-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=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=1deg15min

Information:

Illustration 4 g01633558
(5) 326-7322 Bracket As (13) 250-3895 Spacer (14) 8T-4896 Hard Washer (15) 4L-6459 Bolt
Install the new 326-7322 Bracket As (5) by using four new 250-3895 Spacers (13), four new 4L-6459 Bolts (15), and four new 8T-4896 Hard Washers (14) in the same place where the muffler was previously installed. Refer to Illustration 4.
Illustration 5 g01633569
(4) 326-7321 Connector As (11) 249-3108 Isolation Mount (12) 7X-0618 Hard Washer (16) 8T-4244 Nut (17) 8T-7930 Bolt (19) 8T-4223 Hard Washer
Install the new 326-7321 Connector As (4) on bracket assembly (5) by using three new 249-3108 Isolation Mounts (11), three new 8T-7930 Bolts (17), six new 7X-0618 Hard Washers (12), three new 8T-4223 Hard Washers (19), and three new 8T-4244 Nuts (16). Refer to Illustration 5.
Illustration 6 g01633576
(2) 326-7333 Brace (7) 326-7334 Brace (11) 249-3108 Isolation Mount (12) 7X-0618 Hard Washer (16) 8T-4244 Nut (18) 8T-4176 Bolt (19) 8T-4223 Hard Washer
Install a new 326-7333 Brace (2) and a new 326-7334 Brace (7) to connector assembly (4) by using two new 249-3108 Isolation Mounts (11), two new 8T-4176 Bolts (18), four new 7X-0618 Hard Washers (12), two new 8T-4223 Hard Washers (19) and two new 8T-4244 Nuts (16). Refer to Illustration 6.
Illustration 7 g01633578
(1) 326-7315 Diesel Particulate Filter Gp
Install the new 326-7315 Diesel Particulate Filter Gp (1) onto connector assembly (4). The weight of the diesel particulate filter group is approximately 72.5 kg (160 lb). Refer to Illustration 7.
Illustration 8 g01633590
(9) 326-7320 Filter Clamp Assembly (16) 8T-4244 Nut (19) 8T-4223 Hard Washer (20) 8T-4910 Bolt
Install two new 326-7320 Filter Clamp As (9) by using eight new 8T-4223 Hard Washers (19), four new 8T-4910 Bolts (20) and four new 8T-4244 Nuts (16). Refer to Illustration 8.
Illustration 9 g01633633
(10) 195-3068 Ejector (22) 5P-0597 Hose Clamp (23) 273-3000 Hose (24) 233-7182 Tube
Install the new 195-3068 Ejector (10) to the diesel particulate filter. Refer to Illustration 9.
Install the new 273-3000 Hose (23), and the new 233-7182 Tube (24) to the ejector by using four new 5P-0597 Hose Clamps (22). Refer to Illustration 9.
Illustration 10 g01633714
(6) 326-7328 Tube As (8) 328-8875 Adaptor As (25) 141-1480 Clamp As (27) 202-1838 V-Band Clamp (28) 243-2973 Bellows
Install the new 326-7328 Tube As (6) to the inlet module tube of the diesel particulate filter by using a new 141-1480 Clamp As (25). Refer to Illustration 10.
Install the new 243-2973 Bellows (28) to tube assembly (6) by using a new 202-1838 V-Band