Information injection-pump assembly
ZEXEL
101601-0940
1016010940
ISUZU
5156006051
5156006051
Rating:
Service parts 101601-0940 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
101601-0940
1016010940
ISUZU
5156006051
5156006051
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 and nozzle holder
105101-4970
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
10.95+-0
.5
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
54
52
56
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
F
Rack position
11.25+-0
.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
52
50
54
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) Install pin to get a dimension of ... 4.78 0.25 mm (.188 .010 in.)(2) Install dowel to get a dimension of ... 12.19 0.25 mm (.480 .010 in.)(3) Rack bearing alignment. The center of the rack bearing tab must be within 0.05 mm (.002 in.) of a vertical line that: (a) goes through the center of the rack bearing(b) is parallel to the vertical centerline of injection pump housing The following tooling is available to position the rack bearings correctly: 5P6217 Fixture and 5P6218 Driver.The correct bearing depth [19.0 0.5 mm (.75 .02 in.)] is controlled when driver is stopped by fixture.(4) Position of camshaft bearing joints (X) must be limited to area (A) ... 30 1° When viewed from the Front of the injection pump housing, all three camshaft bearings must be installed with the bearing joint (X) in an area (A) between a vertical position and a position 30° to the Right of vertical. At the same time, oil hole (Y) in the two end bearings (center bearing has no oil hole) must be to the Left of vertical.(5) Distance from bottom of housing to end of rear hollow dowel ... 1.5 0.3 mm (.06 .01 in.)(6) Maximum distance from bottom of housing to end of front hollow dowel ... 1.0 mm (.04 in.)(7) Torque for bolts ... 55 7 N m (40 5 lb.ft.)(8) Distance from rear bearing bore face to installed rear camshaft bearing ... 4.8 0.5 mm (.19 .02 in.)(9) Distance from front bearing bore face to installed front camshaft bearing ... 1.0 0.5 mm (.04 .02 in.) (10) Distance from top surface of housing to top of lower governor drive bearing ... 28.4 0.5 mm (1.12 .02 in.)(11) Install top governor drive bearing (notch end up) with sharp corner even with top surface of housing. Position center of notch so that it is in alignment with the center of oil pressure relief hole (Z) by an amount of ... 10°(12) Install dowel to get a dimension from centerline of fuel injection pump bore to dowel (seal dowel holes with aluminum ball) ... 14.76 0.10 mm (.581 .004 in.)(13) Distance from end of bearing to face of boss on housing ... 73.03 0.51 mm (2.875 .020 in.)(14) Distance between the bearings for the shaft ... 34.80 0.51 mm (1.370 .020 in.)(15) Install pins until they contact bottom of housing casting.