Information injection-pump assembly
ZEXEL
101603-7650
1016037650
ISUZU
1156026931
1156026931
Rating:
Service parts 101603-7650 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-213-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101603-7650
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-1862
as _
Cross reference number
ZEXEL
101603-7650
1016037650
ISUZU
1156026931
1156026931
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 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
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
10.9
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
70.4
68.8
72
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.
9.1
7.8
10.4
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(10.9)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
70.4
69.4
71.4
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.2
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
78
74
82
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
98
98
130
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1275--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1225
Advance angle
deg.
0.5
Load
3/4
Timer adjustment_03
Pump speed
r/min
1275
Advance angle
deg.
0.5
Load
4/4
Timer adjustment_04
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
----------
T1=G13
----------
----------
T1=G13
----------
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=42deg+-5deg b=44deg+-3deg
----------
aa=35mm
----------
a=42deg+-5deg b=44deg+-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=131153-6420 ST=A743 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131153-6420 ST=A743 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=8deg
----------
a=(60deg)
----------
aa=8deg
----------
a=(60deg)
Information:
Problem
The fuel injector clips may fail on certain 3176 Truck Engines which had injectors replaced after January 1, 1991. A new 6I2538 Clip, made from higher strength material, can be installed to increase the reliability and service life of the injector.
Affected Products
Model & Identification Number
The following 3176 Truck Engines if not previously reworked and stamped with "3X" next to Serial No. Plate.
3176 (2YG1-Up)
Parts Needed
Quantity per injector replaced after January 1, 1991
1 - 6I2538 Clip Add injector(s) and related seal(s) if clip is broken in more than three pieces. Add 336044 O- Ring Seal if thrust pad o-ring is damaged.
Action Required
1. Only certain date code injectors installed as field replacements after January 1, 1991 require c-clip replacement.To determine if any c-clips need reworking requires inspection of the block next to the serial plate, the top surface of the injector spring retainer, and the injector date code.
2. Check for "3X" stamped on the block next to the serial number plate. If the block has been stamped, do not proceed with the rework.3. Inspect the top surface of the injector spring retainer for a red or yellow stripe. The red or yellow indicates that the injector has the latest c-clip and that particular injector requires no further action. Engines equipped with a Jake Brake may require removal of the brake to see the top of the injector clearly.4. Injectors without red or yellow stripes require inspection of the identification label on each fuel injector. The labels can be seen just above the top surface of the valve cover base on the right side of the engine. Record the part number and date code of each injector. Refer to Illustration for the location of the part number and date code on the label. 5. Any injectors without red or yellow stripes that have the following date codes require the c-clips to be reworked.LH, MH, AJ, BJ, CJ, DJ, EJ, or FJ
It may not be possible on many engines to determine the date code from an identification label. the following hints may help in these cases.
A) Only certain part numbers were produced during the specified date code range. All others should be omitted from the rework.If the part number can be read, include the following part numbers if tae date codes are LH, MH, AJ, BJ, CJ, DJ, EJ, or FJ.
4P28104P28204P96104P96200R31770R31780R33990R3400If the part number can be read, omit from this rework the following part numbers (Regardless of date code)
9Y99109Y99207E60107E60207E61107E61200R28330R28340R29800R2981B) Early 9Y9910 and 9Y9920 Injectors did not have identification labels. The part numbers are etched into the solenoid case. Omit these injectors from this rework.C) Early 9Y9910 and 9Y9920 Injectors had six (6) sided wrench flats where the solenoid meets the forged body. If the injector has six (6) sided wrench flats, omit the injector from this rework.D) On early injectors the identification labels were prone to falling off. These were not in the specified date code range and can be omitted from this rework.Examples:
6. If an injector requires rework or replacement, refer to
The fuel injector clips may fail on certain 3176 Truck Engines which had injectors replaced after January 1, 1991. A new 6I2538 Clip, made from higher strength material, can be installed to increase the reliability and service life of the injector.
Affected Products
Model & Identification Number
The following 3176 Truck Engines if not previously reworked and stamped with "3X" next to Serial No. Plate.
3176 (2YG1-Up)
Parts Needed
Quantity per injector replaced after January 1, 1991
1 - 6I2538 Clip Add injector(s) and related seal(s) if clip is broken in more than three pieces. Add 336044 O- Ring Seal if thrust pad o-ring is damaged.
Action Required
1. Only certain date code injectors installed as field replacements after January 1, 1991 require c-clip replacement.To determine if any c-clips need reworking requires inspection of the block next to the serial plate, the top surface of the injector spring retainer, and the injector date code.
2. Check for "3X" stamped on the block next to the serial number plate. If the block has been stamped, do not proceed with the rework.3. Inspect the top surface of the injector spring retainer for a red or yellow stripe. The red or yellow indicates that the injector has the latest c-clip and that particular injector requires no further action. Engines equipped with a Jake Brake may require removal of the brake to see the top of the injector clearly.4. Injectors without red or yellow stripes require inspection of the identification label on each fuel injector. The labels can be seen just above the top surface of the valve cover base on the right side of the engine. Record the part number and date code of each injector. Refer to Illustration for the location of the part number and date code on the label. 5. Any injectors without red or yellow stripes that have the following date codes require the c-clips to be reworked.LH, MH, AJ, BJ, CJ, DJ, EJ, or FJ
It may not be possible on many engines to determine the date code from an identification label. the following hints may help in these cases.
A) Only certain part numbers were produced during the specified date code range. All others should be omitted from the rework.If the part number can be read, include the following part numbers if tae date codes are LH, MH, AJ, BJ, CJ, DJ, EJ, or FJ.
4P28104P28204P96104P96200R31770R31780R33990R3400If the part number can be read, omit from this rework the following part numbers (Regardless of date code)
9Y99109Y99207E60107E60207E61107E61200R28330R28340R29800R2981B) Early 9Y9910 and 9Y9920 Injectors did not have identification labels. The part numbers are etched into the solenoid case. Omit these injectors from this rework.C) Early 9Y9910 and 9Y9920 Injectors had six (6) sided wrench flats where the solenoid meets the forged body. If the injector has six (6) sided wrench flats, omit the injector from this rework.D) On early injectors the identification labels were prone to falling off. These were not in the specified date code range and can be omitted from this rework.Examples:
6. If an injector requires rework or replacement, refer to