Information injection-pump assembly
ZEXEL
101603-8060
1016038060
ISUZU
8943937520
8943937520
Rating:
Service parts 101603-8060 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94394-906-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}/22.1{225}
14.
NOZZLE
Include in #1:
101603-8060
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-5040
as _
Cross reference number
ZEXEL
101603-8060
1016038060
ISUZU
8943937520
8943937520
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
132424-0620
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)
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
3.5
3.45
3.55
Rack position
Point A R=A
Point A 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
12.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
99.4
97.8
101
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
260
260
260
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(12.6)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
99.4
98.4
100.4
Basic
*
Fixing the lever
*
Boost pressure
kPa
25.3
25.3
Boost pressure
mmHg
190
190
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(12.6)
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
105.5
102.3
108.7
Fixing the lever
*
Boost pressure
kPa
25.3
25.3
Boost pressure
mmHg
190
190
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-1.15
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
76
72.8
79.2
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
102
102
134
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
900
900
900
Rack position
R1-1.15
Boost pressure
kPa
5.3
4
6.6
Boost pressure
mmHg
40
30
50
Boost compensator adjustment_02
Pump speed
r/min
900
900
900
Rack position
R1(12.6)
Boost pressure
kPa
12
5.3
18.7
Boost pressure
mmHg
90
40
140
Timer adjustment
Pump speed
r/min
1175--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1125
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
3.5
3
4
Load
4/4
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)Adjust so that the boost compensator pushrod protrusion R = Ra at 0 boost.
(4)Boost compensator stroke: BCL
----------
T1=G77 Ra=12+-0.5mm BCL=1.15+-0.1mm
----------
----------
T1=G77 Ra=12+-0.5mm BCL=1.15+-0.1mm
----------
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=10deg+-5deg b=39deg+-3deg
----------
aa=35mm
----------
a=10deg+-5deg b=39deg+-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=12deg
----------
a=(160deg)
----------
aa=12deg
----------
a=(160deg)
Information:
start by:a) remove flywheel 1. Disconnect oil line (1) from the BrakeSaver housing. 2. Remove the bolts and disconnect flanges (2) from the housing. 3. Remove four bolts, manifold (3) and the gasket from the bottom of the BrakeSaver housing. 4. Install tooling (A) on the BrakeSaver housing and rotor. This prevents damage to the rotor and seals when the BrakeSaver is removed. 5. Disconnect two air lines (4) and (5) at the air compressor. 6. Install tooling (B) and fasten a hoist to it. 7. Remove three bolts (6) from the BrakeSaver housing.8. Install two 3/8"-16 NC forcing screws (7) and remove the BrakeSaver. The weight of the BrakeSaver is 168 lb. (76 kg).Install BrakeSaver
1. Install tooling (B) on the BrakeSaver.2. Install two 5/8"-11 NC x 15" guide bolts (1).3. Put BrakeSaver (3) in position with the use of tooling (A) and a hoist.4. Make an alignment of dowel (2) in the crankshaft and the hole in the BrakeSaver. 5. Connect two air lines (4) and (5) to the air compressor. 6. Put O-ring seals (6) and (8) in position on the manifold.7. Put manifold (7) in position and install the bolts. 8. Put the gaskets and manifolds (9) in position and install the bolts. 9. Connect oil line (10) to the BrakeSaver housing.Disassemble BrakeSaver
start by:a) remove BrakeSaver1. Remove tool (A) from the BrakeSaver rotor and housing. Tool (A) prevents damage to the rotor seals and rings at removal of the BrakeSaver. 2. Remove bolts (1) from gear plate (2). Remove the plate. 3. Make identification as to the location of stator (3) with housing (4). Remove bolts (5) and the stator. 4. Turn the stator over and remove spiral ring (6). 5. Turn the stator over again. Remove sleeve assembly (9). Remove O-ring seal (7) and lip type seal (8) from the sleeve. 6. Remove seal (11) from around the housing and the six smaller seals from the oil lines.7. Remove rotor assembly (12).8. Remove seal ring (10) from both sides of the rotor. 9. Remove carrier (13) and wear sleeve (14) with tooling (B) from both sides of the rotor. 10. Remove spiral ring (15). Turn the housing over and remove sleeve assembly (17). Remove the lip type seal and O-ring seal (16) from the sleeve.Assemble Brakesaver
1. Put clean SAE 30 engine oil on the O-ring seal. Install seal (2) on sleeve (1).2. Install the sleeve in the BrakeSaver housing. Make alignment of the notch in the sleeve with the notch in the housing and install the dowel.3. Turn the housing over and install the spiral ring that holds the sleeve in the housing.
Make certain there is clearance behind the spiral ring when it is correctly installed.
4. Heat the carriers and the wear sleeves to a maximum temperature of 300°F (149°C). 5. Install carrier (5) on each side of rotor (3). Install wear sleeve (4) with the taper edge of sleeve in the "UP" position. Make sure the carrier is at bottom on the rotor
1. Install tooling (B) on the BrakeSaver.2. Install two 5/8"-11 NC x 15" guide bolts (1).3. Put BrakeSaver (3) in position with the use of tooling (A) and a hoist.4. Make an alignment of dowel (2) in the crankshaft and the hole in the BrakeSaver. 5. Connect two air lines (4) and (5) to the air compressor. 6. Put O-ring seals (6) and (8) in position on the manifold.7. Put manifold (7) in position and install the bolts. 8. Put the gaskets and manifolds (9) in position and install the bolts. 9. Connect oil line (10) to the BrakeSaver housing.Disassemble BrakeSaver
start by:a) remove BrakeSaver1. Remove tool (A) from the BrakeSaver rotor and housing. Tool (A) prevents damage to the rotor seals and rings at removal of the BrakeSaver. 2. Remove bolts (1) from gear plate (2). Remove the plate. 3. Make identification as to the location of stator (3) with housing (4). Remove bolts (5) and the stator. 4. Turn the stator over and remove spiral ring (6). 5. Turn the stator over again. Remove sleeve assembly (9). Remove O-ring seal (7) and lip type seal (8) from the sleeve. 6. Remove seal (11) from around the housing and the six smaller seals from the oil lines.7. Remove rotor assembly (12).8. Remove seal ring (10) from both sides of the rotor. 9. Remove carrier (13) and wear sleeve (14) with tooling (B) from both sides of the rotor. 10. Remove spiral ring (15). Turn the housing over and remove sleeve assembly (17). Remove the lip type seal and O-ring seal (16) from the sleeve.Assemble Brakesaver
1. Put clean SAE 30 engine oil on the O-ring seal. Install seal (2) on sleeve (1).2. Install the sleeve in the BrakeSaver housing. Make alignment of the notch in the sleeve with the notch in the housing and install the dowel.3. Turn the housing over and install the spiral ring that holds the sleeve in the housing.
Make certain there is clearance behind the spiral ring when it is correctly installed.
4. Heat the carriers and the wear sleeves to a maximum temperature of 300°F (149°C). 5. Install carrier (5) on each side of rotor (3). Install wear sleeve (4) with the taper edge of sleeve in the "UP" position. Make sure the carrier is at bottom on the rotor