Information injection-pump assembly
ZEXEL
101603-7412
1016037412
ISUZU
8943962112
8943962112
Rating:
Service parts 101603-7412 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94397-483-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101603-7412
1016037412
ISUZU
8943962112
8943962112
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
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
After adjusting injection quantity. R=A
Beginning of injection position
Governor side NO.1
Governor 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
-
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
1210--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
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
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=E76
----------
----------
T1=E76
----------
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
----------
aa=35mm
----------
a=11deg+-5deg b=(36.5deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=12.5deg+-5deg b=40deg+-5deg
----------
----------
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%
----------
----------
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)-
----------
aa=10deg
----------
a=(150deg)
----------
aa=10deg
----------
a=(150deg)
Information:
Determine the fuel rail pressure and the injector test engine speed (where the peak pressure was selected). Typically, pressure will start building after 2 to 5 seconds and then there should be sampling for 5 more seconds. Illustration 7 shows an example of selecting the peak pressure and corresponding speed.
Calculate the speed change of the injector test as follows:Injector test speed change equals injector test engine speed minus pump test engine speed.
Determine injector pressure correction using the injector test speed change and Table 5. This will correct for pressure change as speed changes.
Table 5
Injector Pressure Correction Based on Speed Change
Engine speed change (rpm) 0-5 6-10 11-15 16-20 21-25 26-30 31-35
Six-cylinder pressure correction 283 kPa (41 psi) 896 kPa (130 psi) 1455 kPa (211 psi) 2013 kPa (292 psi) 2572 kPa (373 psi) 3130 kPa (454 psi) 3689 kPa (535 psi)
Four-cylinder pressure correction 159 kPa (23 psi) 510 kPa (74 psi) 834 kPa (121 psi) 1151 kPa (167 psi) 1469 kPa (213 psi) 1793 kPa (260 psi) 2110 kPa (306 psi)
If the injector test engine speed is lower than pump test engine speed, then correct the injector pressure by adding the correction as follows:Injector corrected pressure equals injector test pressure plus injector pressure correction.
If the injector test engine speed is higher than pump test engine speed (as can happen when a battery booster is used), then correct the injector test pressure by subtracting the pressure correction as follows:Injector corrected pressure equals injector test pressure minus injector pressure correction.
Calculate injector leakage ratio as follows:Injector leakage ratio equals injector corrected pressure divided by pump test rail pressure.If the Injector leakage ratio is less than 0.85, the injector must be replaced, if the injector leakage is greater than 0.85 the injector is within the required parameters.Remove the fuel line. Replace the cap on the fuel manifold (rail) and injector.
Proceed to the next injector to be checked. Repeat Step 1 through Step 8 for the remaining electronic unit injectors to be tested.
Remove components of 362-9754 Test Kit from the engine. Replace any fuel injection lines that were removed during the procedures. Refer to Disassembly and Assembly, Fuel Injection Lines - Install for the correct procedure.
Reconnect the electronic unit injector harness connectors.Test Kit Data Sheet
Table 6
Fuel Injection Pump Tests Pump Test Rail Pressure Pump Test Engine Speed Minimum Cranking Pressure (MCP) Service
From Pump Test Datalog From Pump