Information injection-pump assembly
ZEXEL
101603-8010
1016038010
ISUZU
8943935850
8943935850
Rating:
Cross reference number
ZEXEL
101603-8010
1016038010
ISUZU
8943935850
8943935850
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
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
11.1
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
69
67.4
70.6
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
9.8+-0.5
Pump speed
r/min
265
265
265
Average injection quantity
mm3/st.
18.2
16.9
19.5
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(11.1)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
69
68
70
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.
103
103
135
Fixing the lever
*
Timer adjustment
Pump speed
r/min
(1220)
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
1.3
0.8
1.8
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
5.5
5
6
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=G16
----------
----------
T1=G16
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Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=43mm
----------
a=12.5deg+-5deg b=(45deg)+-3deg
----------
aa=43mm
----------
a=12.5deg+-5deg b=(45deg)+-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
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)-
(5)Pump vertical direction
(6)Direction of rotation
(7)Pointer
(8)Pointer stamping
(9)Timing device stamping
(10)Timing device
(11)Stamp both at the same time as shown above.
(12)Outside circumference of timing device
(13)Secondary timing stamping position for the No. 1 cylinder's beginning of injection
----------
aa=11deg bb=1deg
----------
a=(150deg) b=1deg
----------
aa=11deg bb=1deg
----------
a=(150deg) b=1deg
Information:
Before any service work is done on the fuel system, the outer surface of the injection pump housing must be clean.
1. Remove the plug from location (1). Install tool (A) in the hole with the large diameter end without the taper down. Move the governor control to the "ON" position until the rack stops against tool (A). The racks are now in center (zero) position.2. Disconnect lines (2) from the fuel injection pumps. Remove the washers. Put caps on all fuel openings. 3. Remove bushings (3) with tooling (B). 4. Install tooling (C). Hold the fuel racks in the center (zero) position and carefully remove the fuel injection pump.
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.
5. Remove spacers (4) from the fuel injection pump housing.
Be careful when the injection pumps are disassembled. Do not cause damage to the surface on the plunger. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
Do not remove gear segment (15) from plunger (10).
6. Remove plunger (10), washer (14) and spring (9) from barrel (8).7. Remove ring (12) from barrel (8) and bonnet (11).8. Remove spring (6), collar (7) and check valve assembly (13) from bonnet (11). Do not disassemble check valve assembly (13).9. Keep seal (5) with the bonnet for use at assembly.Install Fuel Injection Pumps
Make sure the fuel racks are in the center (ZERO) position before the fuel injection pumps are installed.1. Put diesel fuel on all parts to be assembled. 2. Put spring (2), collar (3) and check valve assembly (9) in position in the bonnet.
Do not slide barrel (4) against the check valve assembly when it is assembled. Scratches on the check valve can cause it to leak.
3. Put the bonnet assembly (7) and barrel (4) in position and install ring (8).4. Install spring (5), washer (10) and plunger assembly (6). 5. Put spacer (12) in position in the pump housing bore. Make sure the correct spacer is with each pump. The lobe on the cam must be at its lowest position for easy installation of the fuel injection pumps.6. Hold the fuel racks in the center (ZERO) position when the fuel pumps are installed. Put the space in gear segment (11) in alignment with the groove in barrel (4). 7. Put the injection pump straight down into the housing bore so the space in the gear segment is in alignment with pin (13) and the groove in the barrel is in alignment with dowel (14). Use tool (B) to install the pump. 8. Install seal (1) and bushing (15) in the pump housing bore. If the pump is in the correct position, bushing (15) will