Information injection-pump assembly
ZEXEL
101601-0760
1016010760
ISUZU
5156003113
5156003113
Rating:
Service parts 101601-0760 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-089-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-0760
1016010760
ISUZU
5156003113
5156003113
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle
105015-3600
Nozzle holder
105031-3470
Opening pressure
MPa
18.1+0.5
Opening pressure
kgf/cm2
185+5
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-380
Outer diameter - inner diameter - length (mm) mm 6-2-380
Overflow valve
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
R1(11.1+
-0.5)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
61.4
60.4
62.4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
11.2+-0.
5
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
64
62.4
65.6
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
11.05+-0
.5
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
63.2
61.6
64.8
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
10.85+-0
.5
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
54
52.4
55.6
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
10.85+-0
.5
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
53
51
55
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
F
Rack position
11.1+-0.
5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
48
46
50
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
R2(13.6+
-0.5)
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
89
89
94
Fixing the rack
*
Timer adjustment
Pump speed
r/min
1350+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1500
Advance angle
deg.
2.1
1.6
2.6
Timer adjustment_03
Pump speed
r/min
1600
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)(1) Set at rack limit.
(3)Because the figures in brackets are the target values at torque cam adjustment, perform final adjustment in accordance with governor and injection quantity adjustment standards.
(4)Perform governor spring adjustment by setting lever a.
(5)After adjustment of the lever a setting, set the lever so that idle set point H can be obtained and confirm standard b.
(6)After completing final adjustment, set the lever to obtain J.
(7)Next, confirm rack position R1 or more is obtained when rotation is stopped.
(8)In this condition, move the lever to the full position and confirm standard c. (excess fuel for starting operation limit).
(9)After completing final adjustment, set speed at N1 using lever b.
(10)In this condition, after operating the lever to the full position, confirm no excess fuel for starting (black smoke prevention limit).
(11)For the excess fuel setting for starting rack position point I set the lever to obtain standard c in step (8) and then set the rack limit.
----------
T1=01 R1=12mm N1=225r/min
----------
----------
T1=01 R1=12mm N1=225r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Fix idle side stopper bolt so that the lever setting is 'b'.
----------
----------
a=40deg+-5deg b=39deg+-3deg
----------
----------
a=40deg+-5deg b=39deg+-3deg
Information:
(1) Nut (4K0367)(2) Bearing (9U6877)(3) Washer (5P8247)(4) Bridge plate (9U7259)(5) Bolts (5/16)(6) Threaded rod puller stud (221-9778)(7) Threaded end
Install the remaining parts of Tool B on the threadedrod assembly (item 6).
Lubricate the threads on (item 6).
Tighten nut (item 1) in order to remove the unitinjector sleeve. Do not use an impact wrench.
After the sleeve is removed, use the large 4C5552wire brush to remove dirt and sealant from the bore. Squirt isopropyl alcoholor brake cleaner into the bore to remove oil. Use paper towels and swabsto remove all debris from the bore. Ensure the injector bore and fuel railare clean and free from debris.
Any sealant, fuel, oil or debris willprevent the sealant from properly curing. Improper cleaning will lead toa poor sealing surface and leak path.
Table 3 Unit Injector Sleeve ? InstallRequired Tools
ToolA
Part Number Description Quantity
2219777 Sleeve Installer 1
4C9507 Locktite 620 Sealant 1 Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure the o-ring (8T7878) is in place on the2219777 sleeve installer
Place the 1785037 unit injector sleeve on ToolA.
Clean the sleeve with isopropyl alcohol and wipedry with as clean paper towel. Note: Make sure the sleeve is free ofall debris, oil and fuel.
Apply 4C9507 Locktite 620 sealant (shake wellbefore using, sealant can separate) to the upper land and lower land ofthe unit injector sleeve.
Surfaces to be sealed must be freeof oil, grease, fuel, etc.
Install the unit injector sleeve into the injectorsleeve bore.
Use a hammer to drive the sleeve into the headuntil the sleeve bottoms out.
Wipe all excess anaerobic from the injector borewith a paper towel and swab.
Stamp AH on the front left top of the cylinderhead near the HEP 8 pump to verify the rework has been completed.
Wait approximately two (2) hours atroom temperature (70F) before filling the engine with fuel or coolant.Longer curing time is needed at lower temperatures.Unit injectors ? Installation procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Part Number Description Quantity
Tool A 1492955 Seal Protector 1
Tool B 1492956 Seal Installer 1
Install injection actuation pressure sensor. Torquethe sensor to 10 2 N m (88 18 lb in).
Install the fuel lines and fittings as needed.Torque to specifications.
Lubricate the O-Ring seals and the sleeve boreof the injector sparingly with clean engine oil.
Install injector in the cylinder head. Positionthe injector into the cylinder head. Use your hand to install the injectorinto the cylinder head. Install socket head bolt on the exhaust side ofthe hold down bracket. Tighten the exhaust side of socket head bolt untilthe bolt is seated. Install and tighten the inlet side of socket head boltto a torque of 12 1 N m (9 1 lb ft).
Install the valve mechanism cover. Refer to Disassemblyand Assembly, "Valve Mechanism Cover - Remove and Install".
If the o-rings are damaged and needreplaced.
Use Tool (A) and Tool (B) to install the upper high-pressure seal pack.
Install the upper seal pack first. Then installthe middle seal pack. Finally, install the bottom O-Ring Seal.
Install Tool (A) on the injector.
Use Tool (B) to install backup rings and O-ringseal on the unit injector. Lubricate the O-ring seals and
Install the remaining parts of Tool B on the threadedrod assembly (item 6).
Lubricate the threads on (item 6).
Tighten nut (item 1) in order to remove the unitinjector sleeve. Do not use an impact wrench.
After the sleeve is removed, use the large 4C5552wire brush to remove dirt and sealant from the bore. Squirt isopropyl alcoholor brake cleaner into the bore to remove oil. Use paper towels and swabsto remove all debris from the bore. Ensure the injector bore and fuel railare clean and free from debris.
Any sealant, fuel, oil or debris willprevent the sealant from properly curing. Improper cleaning will lead toa poor sealing surface and leak path.
Table 3 Unit Injector Sleeve ? InstallRequired Tools
ToolA
Part Number Description Quantity
2219777 Sleeve Installer 1
4C9507 Locktite 620 Sealant 1 Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure the o-ring (8T7878) is in place on the2219777 sleeve installer
Place the 1785037 unit injector sleeve on ToolA.
Clean the sleeve with isopropyl alcohol and wipedry with as clean paper towel. Note: Make sure the sleeve is free ofall debris, oil and fuel.
Apply 4C9507 Locktite 620 sealant (shake wellbefore using, sealant can separate) to the upper land and lower land ofthe unit injector sleeve.
Surfaces to be sealed must be freeof oil, grease, fuel, etc.
Install the unit injector sleeve into the injectorsleeve bore.
Use a hammer to drive the sleeve into the headuntil the sleeve bottoms out.
Wipe all excess anaerobic from the injector borewith a paper towel and swab.
Stamp AH on the front left top of the cylinderhead near the HEP 8 pump to verify the rework has been completed.
Wait approximately two (2) hours atroom temperature (70F) before filling the engine with fuel or coolant.Longer curing time is needed at lower temperatures.Unit injectors ? Installation procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Part Number Description Quantity
Tool A 1492955 Seal Protector 1
Tool B 1492956 Seal Installer 1
Install injection actuation pressure sensor. Torquethe sensor to 10 2 N m (88 18 lb in).
Install the fuel lines and fittings as needed.Torque to specifications.
Lubricate the O-Ring seals and the sleeve boreof the injector sparingly with clean engine oil.
Install injector in the cylinder head. Positionthe injector into the cylinder head. Use your hand to install the injectorinto the cylinder head. Install socket head bolt on the exhaust side ofthe hold down bracket. Tighten the exhaust side of socket head bolt untilthe bolt is seated. Install and tighten the inlet side of socket head boltto a torque of 12 1 N m (9 1 lb ft).
Install the valve mechanism cover. Refer to Disassemblyand Assembly, "Valve Mechanism Cover - Remove and Install".
If the o-rings are damaged and needreplaced.
Use Tool (A) and Tool (B) to install the upper high-pressure seal pack.
Install the upper seal pack first. Then installthe middle seal pack. Finally, install the bottom O-Ring Seal.
Install Tool (A) on the injector.
Use Tool (B) to install backup rings and O-ringseal on the unit injector. Lubricate the O-ring seals and