101603-7531 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037531 8943969251

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-7531 1016037531

ISUZU 8943969251 8943969251

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Service parts 101603-7531 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4960

3. GOVERNOR 105931-7611

4. SUPPLY PUMP 105210-5120

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:

101492-0530 as _

101492-0531

101603-7531 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-7531 1016037531

ISUZU 8943969251 8943969251

Zexel num

Bosch num

Firm num

Name

101603-7531
101603-7532

8943969251 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=60mm
----------
a=16deg+-5deg b=29deg+-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=1deg

Information:

Installation Procedure
The installation procedure that follows is specific for the listed machine.Diesel Particulate Filter Installation
Illustration 6 g01782176
(2) 331-9206 Bracket As (15) 8T-4223 Hard Washer (16) 8F-6437 Washer (17) 8T-4139 Bolt (19) 6V-8149 Nut
Install the new 331-9206 Bracket As (2) on top of the hood using two new 6V-87149 Nuts (19), one new 8F-6437 Washer (16), three new 8T-4223 Hard Washers (16), and two new 8T-4139 Bolts (17). Refer to Illustration 6.
Illustration 7 g01782178
(3) 331-9212 Bracket (20) 8T-3597 Weld Nut
Connect 331-9212 Bracket (3) to the hood and to bracket assembly (2) using four new 8T-3597 Weld Nuts (20), three new washers (16), one new hard washer (15), and four new bolts (17). Refer to Illustration 7.
Illustration 8 g01782181
(6) 295-3044 Exhaust Support Gp (Lower half)
Install the lower halves of 295-3044 Exhaust Support Gp (6) on bracket assembly (2) using two new washers (16), two new hard washers (15), and four new bolts (17). Refer to Illustration 8.
Illustration 9 g01782193
(1) 331-8928 Diesel Particulate Filter Gp (6) 295-3044 Exhaust Support Gp (Upper half) (6a) Bolt (6b) Hard washer (6c) Weld nut
Place 331-8928 Diesel Particulate Filter Gp (1) onto the two lower halves of exhaust support group (6). The weight of the diesel particulate filter group is approximately 44 kg (97 lb). Refer to Illustration 9.
Install the two upper halves of exhaust support group (6) onto the lower halves of exhaust support group (6) using four hard washers (6b), four weld nuts (6c), and four bolts (6a). Refer to Illustration 9.
Illustration 10 g01782194
(a) Outlet module tube (11) 7S-8735 Clamp (13) 255-2899 Tail Pipe As (18) 8T-4186 Bolt (21) 8T-4133 Nut
Connect the new 255-2899 Tail Pipe As (13) to outlet module tube (a) of diesel particulate filter group (1) using one new 7S-8735 Clamp (11), one new 8T-4186 Bolt (18) and one new 8T-4133 Nut (21). Refer to Illustration 10.
Illustration 11 g01782200
(b) Inlet module tube (4) 331-9214 Filter Tube As (9) 8T-6765 Pipe Plug (8) 241-6170 Plug (12) 209-4589 Clamp
Connect the new 331-9214 Filter Tube As (4) to inlet module tube (b) of diesel particulate filter group using one new 209-4589 Clamp (12). Refer to Illustration 11.
Install the new 8T-6765 Pipe Plug (9) and 241-6170 Plug (8) onto the respective bosses provided on filter tube assembly (4). Refer to Illustration 11.
Illustration 12 g01782206
(7) 270-0112 Bellows
Connect the new 270-0112 Bellows (7) to filter tube assembly (4) using one clamp new (12). Refer to Illustration 12.
Illustration 13 g01782215
(5) 331-9213 Filter Tube
Connect the new 331-9213 Filter Tube (5) to bellows (7) using one new clamp (12). Refer to Illustration 13.
Illustration 14 g01782235
(10) 7E-3870 Muffler Clamp (14) 146-9734 Exhaust Elbow
Connect the new 146-9734 Exhaust Elbow (14) to filter tube (5) using a new 7E-3870 Muffler Clamp (10). Refer to