Information injection-pump assembly
ZEXEL
101603-8030
1016038030
ISUZU
8943937150
8943937150
Rating:
Cross reference number
ZEXEL
101603-8030
1016038030
ISUZU
8943937150
8943937150
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
11.5
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
77.7
76.1
79.3
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(11.5)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
77.7
76.7
78.7
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.
90.7
86.7
94.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.2
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
61.8
58.6
65
Fixing the lever
*
Injection quantity adjustment_06
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
1300--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1250
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
4
3.5
4.5
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=G80
----------
----------
T1=G80
----------
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=36deg+-3deg
----------
aa=35mm
----------
a=11deg+-5deg b=36deg+-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 ACS
(A) Housing
(B) Snap ring
(C) adjusting screw
(D) Set screw
(E): Push rod
(F) Spacer
1. Adjustment of the aneroid compensator
(1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1.
(2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2.
(3)(C) Turn the screw to adjust the beginning of aneroid compensator operation.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Adjust using screw C to obtain the performance shown in the graph above.
(3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=900r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(11.5)mm Rb=(R1-0.85)mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=77.7+-1mm3/st Q2=61.7+-1.6mm3/st
----------
N1=900r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(11.5)mm Rb=(R1-0.85)mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=77.7+-1mm3/st Q2=61.7+-1.6mm3/st
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. Loosen bolt (2) on belt tightener bracket (1).2. Remove the belts from the idler pulley.3. Remove bolt (3) that holds the bracket to the engine cover. Remove the idler pulley and the bracket as a unit.Install Belt Tightener Idler Pulley
1. Put the pulley and bracket as a unit in position on the engine cover.2. Install the bolts loosely that hold the pulley and bracket to the engine cover.3. Install the belts on the pulleys and make belt adjustment so movement (deflection) is 7/8 in. (22.2 mm) under 25 lb. (110 N) force halfway between pulleys.4. Tighten the 5/8" diameter bolt on the belt tightener bracket to a torque of 75 10 lb.ft. (100 14 N m). Tighten the 1/2" diameter bolt to a torque of 40 5 lb.ft. (55 7 N m).Disassemble Belt Tightener Idler Pulley
start by: a) remove belt tightener idler pulley 1. Remove bolts (1) and cover (2). 2. Remove bolts (5) and washer (6) from bracket (3).3. Lift pulley (4) from the bracket. 4. Remove O-ring seal (7), bearing (11) and spacer (8) from the pulley.5. Remove spacer (10), lip type seal (12) and bearing (9) from the rear of the pulley.Assemble Belt Tightener Idler Pulley
1. Install the bearing in the rear of pulley (1) with tooling (A).2. Put 5P960 Multipurpose Grease on the lips of the seal. Install the lip type seal with the lip toward the rear surface of the pulley with tooling (B).3. Install the spacer in the pulley. Install the spacer in the O-ring seal until it makes contact with the bearing. 4. Install the spacer from the front side of the pulley. Install bearing (2) with tooling (A) in the pulley (1).5. Put O-ring seal (3) in position on the pulley. Put the pulley in position on pulley bracket shaft (4).6. Install the washer and the bolts that hold the pulley on the bracket. Install the cover and the bolts on the pulley.7. Fill pulley with 5P960 Multipurpose Grease.end by:a) install belt tightener idler pulley
1. Put the pulley and bracket as a unit in position on the engine cover.2. Install the bolts loosely that hold the pulley and bracket to the engine cover.3. Install the belts on the pulleys and make belt adjustment so movement (deflection) is 7/8 in. (22.2 mm) under 25 lb. (110 N) force halfway between pulleys.4. Tighten the 5/8" diameter bolt on the belt tightener bracket to a torque of 75 10 lb.ft. (100 14 N m). Tighten the 1/2" diameter bolt to a torque of 40 5 lb.ft. (55 7 N m).Disassemble Belt Tightener Idler Pulley
start by: a) remove belt tightener idler pulley 1. Remove bolts (1) and cover (2). 2. Remove bolts (5) and washer (6) from bracket (3).3. Lift pulley (4) from the bracket. 4. Remove O-ring seal (7), bearing (11) and spacer (8) from the pulley.5. Remove spacer (10), lip type seal (12) and bearing (9) from the rear of the pulley.Assemble Belt Tightener Idler Pulley
1. Install the bearing in the rear of pulley (1) with tooling (A).2. Put 5P960 Multipurpose Grease on the lips of the seal. Install the lip type seal with the lip toward the rear surface of the pulley with tooling (B).3. Install the spacer in the pulley. Install the spacer in the O-ring seal until it makes contact with the bearing. 4. Install the spacer from the front side of the pulley. Install bearing (2) with tooling (A) in the pulley (1).5. Put O-ring seal (3) in position on the pulley. Put the pulley in position on pulley bracket shaft (4).6. Install the washer and the bolts that hold the pulley on the bracket. Install the cover and the bolts on the pulley.7. Fill pulley with 5P960 Multipurpose Grease.end by:a) install belt tightener idler pulley