Information injection-pump assembly
ZEXEL
101603-7890
1016037890
ISUZU
8943934770
8943934770
Rating:
Cross reference number
ZEXEL
101603-7890
1016037890
ISUZU
8943934770
8943934770
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)
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
3.6
3.55
3.65
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
11.3
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
73.8
72.2
75.4
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
265
265
265
Average injection quantity
mm3/st.
8.8
7.5
10.1
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(11.3)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
73.8
72.8
74.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
96
96
104
Fixing the lever
*
Timer adjustment
Pump speed
r/min
550--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
3
2.5
3.5
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)RACK LIMIT
----------
T1=G59
----------
----------
T1=G59
----------
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=(38deg)+-3deg
----------
aa=35mm
----------
a=11deg+-5deg b=(38deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
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=14deg
----------
a=(150deg)
----------
aa=14deg
----------
a=(150deg)
Information:
(1) Torque for fuel injection line nut ... 40 7 N m (30 5 lb.ft.)(2) Torque for retainer ... 48 7 N m (35 5 lb.ft.)(3) Torque for bleed screw ... 2.2 0.8 N m (20 7 lb.in.) Always use a new washer (seal) anytime the bleed screw is loosened or removed.(4) Washer. Make sure the correct washer is used when the nozzle assembly is installed.(5) Put liquid soap on rubber O-ring and bore in head before assembly.(6) Put 5P3931 Anti-Seize Compound on the threads of the adapter before installation. Torque for the adapter ... 205 14 N m (150 10 lb.ft.)See Testing And Adjusting section, for fuel injection nozzle test procedure.Earlier Engines
(1) Nut for fuel line. Hold adapter assembly (2) when nut (1) is loosened or tightened. Torque for the nut ... 40 7 N m (30 5 lb.ft.)(2) Adapter assembly.(3) Torque for bleed screw ... 1.6 0.4 N m (14 4 lb.in.)Always use a new washer (seal) anytime the bleed screw is loosened or removed.(4) Washer. Make sure the correct washer is used when the nozzle assembly is installed. Check the Engine Arrangement for the correct part number to use.(5) Torque for clamp bolt ... 31 7 N m (23 5 lb.ft.)(6) Put liquid soap on rubber O-ring and bore in head before assembly.(7) Put 5P3931 Anti-Seize Compound on the threads of the adapter before installation. Torque for the adapter ... 205 14 N m (150 10 lb.ft.)Engines With Capsule-Type Nozzles
Earlier Engines
(1) Torque for
(1) Nut for fuel line. Hold adapter assembly (2) when nut (1) is loosened or tightened. Torque for the nut ... 40 7 N m (30 5 lb.ft.)(2) Adapter assembly.(3) Torque for bleed screw ... 1.6 0.4 N m (14 4 lb.in.)Always use a new washer (seal) anytime the bleed screw is loosened or removed.(4) Washer. Make sure the correct washer is used when the nozzle assembly is installed. Check the Engine Arrangement for the correct part number to use.(5) Torque for clamp bolt ... 31 7 N m (23 5 lb.ft.)(6) Put liquid soap on rubber O-ring and bore in head before assembly.(7) Put 5P3931 Anti-Seize Compound on the threads of the adapter before installation. Torque for the adapter ... 205 14 N m (150 10 lb.ft.)Engines With Capsule-Type Nozzles
Earlier Engines
(1) Torque for