Information injection-pump assembly
ZEXEL
101603-8300
1016038300
ISUZU
8943947620
8943947620
Rating:
Service parts 101603-8300 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94394-787-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101603-8300
as INJECTION-PUMP ASSEMBLY
Include in #2:
104742-1382
as _
Cross reference number
ZEXEL
101603-8300
1016038300
ISUZU
8943947620
8943947620
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.
66.9
65.3
68.5
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.
9
7.7
10.3
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(11.1)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
66.9
65.9
67.9
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.1
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
78.5
74.5
82.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.3
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
49.7
46.5
52.9
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
99
99
131
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1210--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1160
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
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
(2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=G22
----------
----------
T1=G22
----------
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=14deg+-5deg b=38deg+-3deg
----------
aa=35mm
----------
a=14deg+-5deg b=38deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=62.5mm
----------
a=25deg+-5deg b=29deg+-5deg
----------
aa=62.5mm
----------
a=25deg+-5deg b=29deg+-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)Move b deg and 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
----------
a=(150deg) b=1deg
----------
aa=11deg
----------
a=(150deg) b=1deg
Information:
Before any service work is to be done on the fuel system the outer surface of the injection pump housing must be clean.
1. Remove cover assembly (1) from the pump housing. Remove the spring for the bypass valve. 2. Loosen bushing (2) from the pump housing with tool (A). Do not loosen screws (3) when removing or installing the pumps. If the levers are moved, the fuel pump adjustment will be changed.3. Remove the fuel injection pump from the pump housing. The sleeve on the plunger will slide off the lever as the pump is removed.Install Fuel Injection Pumps
1. Put fuel injection pump (1) in the bore of the pump housing.2. Sleeve (2) must be engaged with lever (3) when installed correctly.
If the levers (3) have been moved on the shaft, fuel pump adjustment must be made. (See TESTING AND ADJUSTING).
3. Tighten the bushing with tool (A) to a torque of 70 5 lb.ft. (95 7 N m). 4. Put the spring and bypass valve in place. Install the cover assembly on the pump housing. Be sure spring (4) is in position in the cover.Disassemble Fuel Injection Pumps
start by: a) remove fuel injection pumps1. Remove bushing (1) from bonnet (2).2. Remove ring (3) from the bonnet and barrel (7). Remove check valve (6) and spring (4) from the bonnet.3. Remove spring (8) and washer (5). Remove plunger (9) and sleeve (10). Keep the plunger and sleeve with their respective barrel for installation. Do not use plungers, sleeves or barrels with other plungers, sleeves or barrels.Assemble Fuel Injection Pumps
1. Install sleeve (4), plunger (5), spring (2) and washer (3) on barrel (1).
Make sure the sleeve is installed with the thin edge up.
Be sure the sleeve and plunger are installed in their original barrel. Make sure the large hole in the plunger is up.2. Install the check valve and spring in the bonnet. Connect the barrel and bonnet and install the ring. Install the bushing on the bonnet.end by: a) install fuel injection pumps