Information injection-pump assembly
ZEXEL
101603-7432
1016037432
ISUZU
8943961612
8943961612
Rating:
Cross reference number
ZEXEL
101603-7432
1016037432
ISUZU
8943961612
8943961612
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=F10
----------
----------
T1=F10
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=60mm
----------
a=28.5deg+-5deg b=(36.5deg)+-3deg
----------
aa=60mm
----------
a=28.5deg+-5deg b=(36.5deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=32.5deg+-5deg b=40deg+-5deg
----------
----------
a=32.5deg+-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=11deg
----------
a=(150deg)
----------
aa=11deg
----------
a=(150deg)
Information:
1. Remove the oil outlet line (1) for oil pump.2. Remove the bolts (2) and locks, and remove the oil pump. Weight of oil pump is 40 lb. (17 kg).Install Oil Pump
1. Put the oil pump in position on engine, and install the bolts and locks.2. Install the oil outlet line for pump.end by: a) install oil panDisassemble Oil Pump
start by: a) remove oil pump 1. Remove suction bell (2). 2. Remove cover (4) and screen (5) from suction bell.3. Remove the cover (1) from bypass valve.4. Remove the bypass valve spring and plunger for the oil pump.5. Remove the cotter pin, and loosen nut (3). 6. Install tool setup (A) and make the gear separate from shaft.7. Remove tool setup (A), nut (3), and gear. Remove the woodruff key from shaft. 8. Remove the bolts (6) and locks. Remove cover assembly (7).9. Remove the oil pump gears.10. Remove the bolts (9) and locks. Remove the cover assembly (8).11. Remove the bearings from cover assemblies (7) and (8).Assemble Oil Pump
1. Use tool setup (A) to install the bearings in the cover assemblies. 2. Put cover assembly (1) in position on body, and install the bolts and locks.3. Put clean oil on the oil pump gears and on the bearings in the cover assemblies.4. Put the oil pump gears in position on cover assembly (2), and install the cover assembly. Install the bolts and locks.5. Install the woodruff key in shaft.6. Put the drive gear in position on shaft, and install the nut and washer. Tighten the nut to 60 lb.ft. (8.3 mkg) plus the amount needed to put holes for cotter pin in alignment. Install the cotter pin. 7. Install the bypass valve plunger (3) and spring (4). Install the cover for bypass valve. 8. Put the screen assembly (5) in position in the suction bell, and install the cover.9. Install the suction bell on oil pump.end by: a) install oil pump
1. Put the oil pump in position on engine, and install the bolts and locks.2. Install the oil outlet line for pump.end by: a) install oil panDisassemble Oil Pump
start by: a) remove oil pump 1. Remove suction bell (2). 2. Remove cover (4) and screen (5) from suction bell.3. Remove the cover (1) from bypass valve.4. Remove the bypass valve spring and plunger for the oil pump.5. Remove the cotter pin, and loosen nut (3). 6. Install tool setup (A) and make the gear separate from shaft.7. Remove tool setup (A), nut (3), and gear. Remove the woodruff key from shaft. 8. Remove the bolts (6) and locks. Remove cover assembly (7).9. Remove the oil pump gears.10. Remove the bolts (9) and locks. Remove the cover assembly (8).11. Remove the bearings from cover assemblies (7) and (8).Assemble Oil Pump
1. Use tool setup (A) to install the bearings in the cover assemblies. 2. Put cover assembly (1) in position on body, and install the bolts and locks.3. Put clean oil on the oil pump gears and on the bearings in the cover assemblies.4. Put the oil pump gears in position on cover assembly (2), and install the cover assembly. Install the bolts and locks.5. Install the woodruff key in shaft.6. Put the drive gear in position on shaft, and install the nut and washer. Tighten the nut to 60 lb.ft. (8.3 mkg) plus the amount needed to put holes for cotter pin in alignment. Install the cotter pin. 7. Install the bypass valve plunger (3) and spring (4). Install the cover for bypass valve. 8. Put the screen assembly (5) in position in the suction bell, and install the cover.9. Install the suction bell on oil pump.end by: a) install oil pump