101603-7620 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data


Information injection-pump assembly

ZEXEL 101603-7620 1016037620
ISUZU 8943935600 8943935600

Cross reference number

ZEXEL 101603-7620 1016037620
ISUZU 8943935600 8943935600


Zexel num Bosch num Firm num Firm Name
101603-7620 
101603-7621 
  8943935600  ISUZU INJECTION-PUMP ASSEMBLY
6HE1-S * K

Calibration Data:



Adjustment conditions
Test oil   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   L
Left


Injection timing adjustment
Direction of rotation (viewed from drive side)   L
Left
Injection order   1-5-3-6- 2-4
Pre-stroke mm   4.2 4.15 4.25
Rack position   R=A
After adjusting injection quantity.
Beginning of injection position   NO.1
Governor side
Difference between angles 1 deg.   60 59.5 60.5
Cal 1-5
Difference between angles 2 deg.   120 119.5 120.5
Cal 1-3
Difference between angles 3 deg.   180 179.5 180.5
Cal 1-6
Difference between angles 4 deg.   240 239.5 240.5
Cyl.1-2
Difference between angles 5 deg.   300 299.5 300.5
Cal 1-4


Injection quantity adjustment
Adjusting point   -
Rack position   11.1
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   69 67.4 70.6
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   9.8+-0.5
Pump speed r/min   265 265 265
Average injection quantity mm3/st.   18.2 16.9 19.5
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(11.1)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   69 68 70
Basic   *
Fixing the lever   *


Injection quantity adjustment_04
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

Test data 101603-7620 N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=G16
----------



Speed control lever angle

Test data 101603-7620 F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=43mm
----------
a=12.5deg+-5deg b=(45deg)+-3deg



Stop lever angle

Test data 101603-7620 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

Test data 101603-7620 (1)Pump vertical direction (2)Position of timer's threaded hole at the 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)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 bb=1deg
----------
a=(150deg)





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Group cross 101603-7620 ZEXEL

Isuzu 

101603-7600 
101603-7601 
  8943969280  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7601 
101603-7602 
  8943969281  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7602 
101603-7603 
9 400 619 723  8943969282  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7603  9 400 615 199  8943969283  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7610 
101603-7611 
F 019 Z10 502  1156027600  INJECTION-PUMP ASSEMBLY
6SA1
101603-7611  9 400 619 600  1156027601  INJECTION-PUMP ASSEMBLY
6SA1
101603-7612  F 019 Z10 503    INJECTION-PUMP ASSEMBLY

Isuzu 

101603-7620 
101603-7621 
  8943935600  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7621  9 400 615 200  8943935601  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7630 
101603-7631 
  8943932740  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7631 
101603-7632 
  8943932741  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7632  9 400 615 201  8943932742  INJECTION-PUMP ASSEMBLY
6HE1-S
101603-7640      INJECTION-PUMP ASSEMBLY

Isuzu 

101603-7641 
101603-7642 
  1156026920  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-7642 
101603-7643 
  1156026921  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-7643  9 400 615 202  1156026922  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-7650 
101603-7651 
  1156026931  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-7651  9 400 615 203  1156026932  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-7660    1156026940  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-7670 
101603-7671 
  1156026950  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-7671 
101603-7672 
F 019 Z10 601  1156026951  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-7672  9 400 615 204  1156026952  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-7680      INJECTION-PUMP ASSEMBLY

Isuzu 

101603-7681 
101603-7682 
  1156026960  INJECTION-PUMP ASSEMBLY
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101603-7682 
101603-7683 
  1156026961  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-7683  9 400 615 205  1156026962  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-7690  9 400 615 206    INJECTION-PUMP ASSEMBLY
6BG1-S

Isuzu 

101603-7690  9 400 615 206  1156026970  INJECTION-PUMP ASSEMBLY
6BG1-S
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