Information injection-pump assembly
ZEXEL
101603-7441
1016037441
ISUZU
1156026522
1156026522
Rating:
Cross reference number
ZEXEL
101603-7441
1016037441
ISUZU
1156026522
1156026522
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
105780-8140
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
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)
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
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
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
-
Rack position
13.3
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
98.6
97
100.2
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
275
275
275
Average injection quantity
mm3/st.
8
6.7
9.3
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(13.3)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
98.6
97.6
99.6
Basic
*
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.15
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
98.6
95.4
101.8
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-0.
55)
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
78.6
75.4
81.8
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2-1.35
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
54
50.8
57.2
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
93
93
125
Fixing the lever
*
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
R2-1.35
Boost pressure
kPa
3.3
3.3
6
Boost pressure
mmHg
25
25
45
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
R2(R1-0.
55)
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Timer adjustment
Pump speed
r/min
(1170)
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1325
Advance angle
deg.
1.5
1
2
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
2
1.5
2.5
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.
(3)Boost compensator stroke
----------
T1=F19
----------
----------
T1=F19
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=43deg+-5deg b=(37deg)+-3deg
----------
aa=35mm
----------
a=43deg+-5deg b=(37deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-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=131153-3720 ST=A716 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131153-3720 ST=A716 L1=1mm L2=3.6+-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=(60deg)
----------
aa=10deg
----------
a=(60deg)
Information:
2. Disconnect the fuel injection lines (2) from pump housing. Put plugs or caps in all lines and openings.3. Remove the three bolts that hold the fuel filter (3) to the aftercooler housing.4. Disconnect the sensing line (1) for the fuel ratio control from the aftercooler housing. 5. Disconnect the oil supply line (4) from the turbocharger.6. Remove the two water lines (5). 7. Disconnect the water outlet line (6) for the air compressor from the cylinder head.8. Remove the bolts (7) that fasten the cylinder head to the cylinder block. 9. Install 3/8"-16NC forged eyebolts in the cylinder head. Fasten a hoist and remove the cylinder head assembly. Weight of cylinder head assembly is 575 lb. (260 kg). Be sure to install a new gasket between the spacer plate and the cylinder block before installing the cylinder head assembly. See REMOVE and INSTALL SPACER PLATE in DISASSEMBLY AND ASSEMBLY.Install Cylinder Head Assembly
1. Clean the top surface of spacer plate and the surface it is in contact with on the cylinder head.2. Install the cylinder head gasket, water seals, and gasket on timing gear cover. 3. Install the 3/8"-16NC forged eyebolts in the cylinder head. Fasten a hoist and put the cylinder head assembly into position on the engine. Make sure the gear (1) in cylinder head is engaged with drive gear (2). 4. Put 9M3710 Anti-Seize Compound on the threads of the bolts for cylinder head. Install the bolts and washers. Tighten the bolts as follows: 1 -Tighten all bolts in number order to 135 lb.ft. (18.7 mkg).2 -Tighten all bolts in number order to 185 5 lb.ft. (25.6 0.7 mkg).3 -Tighten all bolts using hand torque only to 185 5 lb.ft. (25.6 0.7 mkg). 5. Install the two water lines (4).6. Connect the oil supply line (3) to the turbocharger.7. Connect the water outlet line (5) for the air compressor to the cylinder head. 8. Connect the sensing line (6) for the fuel ratio control to the aftercooler housing.9. Put the fuel filter in position, and install the three bolts.10. Remove the plugs and fuel injection lines and pumps. Connect the fuel injection lines (7) to the pumps. Tighten the nuts on fuel lines to 30 5 lb.ft. (4.1 0.7 mkg).11. Fill the cooling system with coolant.end by: a) install camshaft housingb) install fan drive
1. Clean the top surface of spacer plate and the surface it is in contact with on the cylinder head.2. Install the cylinder head gasket, water seals, and gasket on timing gear cover. 3. Install the 3/8"-16NC forged eyebolts in the cylinder head. Fasten a hoist and put the cylinder head assembly into position on the engine. Make sure the gear (1) in cylinder head is engaged with drive gear (2). 4. Put 9M3710 Anti-Seize Compound on the threads of the bolts for cylinder head. Install the bolts and washers. Tighten the bolts as follows: 1 -Tighten all bolts in number order to 135 lb.ft. (18.7 mkg).2 -Tighten all bolts in number order to 185 5 lb.ft. (25.6 0.7 mkg).3 -Tighten all bolts using hand torque only to 185 5 lb.ft. (25.6 0.7 mkg). 5. Install the two water lines (4).6. Connect the oil supply line (3) to the turbocharger.7. Connect the water outlet line (5) for the air compressor to the cylinder head. 8. Connect the sensing line (6) for the fuel ratio control to the aftercooler housing.9. Put the fuel filter in position, and install the three bolts.10. Remove the plugs and fuel injection lines and pumps. Connect the fuel injection lines (7) to the pumps. Tighten the nuts on fuel lines to 30 5 lb.ft. (4.1 0.7 mkg).11. Fill the cooling system with coolant.end by: a) install camshaft housingb) install fan drive