Information injection-pump assembly
ZEXEL
101603-8343
1016038343
ISUZU
8943901620
8943901620
Rating:
Service parts 101603-8343 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94393-335-1
12.
Open Pre:MPa(Kqf/cm2)
16.2{165}/18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101603-8343
1016038343
ISUZU
8943901620
8943901620
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
4.7
4.65
4.75
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
12.3
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
87
85.4
88.6
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
9.5+-0.5
Pump speed
r/min
275
275
275
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(12.3)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
87
86
88
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
(R1+0.1)
Pump speed
r/min
1425
1425
1425
Average injection quantity
mm3/st.
98
94.8
101.2
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.15
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
75
71.8
78.2
Fixing the lever
*
Timer adjustment
Pump speed
r/min
905--
Advance angle
deg.
0
0
0
Load
3/5
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
855
Advance angle
deg.
0.3
Load
3/5
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
1.5
1
2
Load
5/5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1110
Advance angle
deg.
1.5
1
2
Load
3/5
Timer adjustment_05
Pump speed
r/min
1450
Advance angle
deg.
7
6.5
7.5
Load
5/5
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.
----------
T1=L49
----------
----------
T1=L49
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=33mm
----------
a=11deg+-5deg b=43deg+-3deg
----------
aa=33mm
----------
a=11deg+-5deg b=43deg+-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=131150-0420 ST=A792 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131150-0420 ST=A792 L1=1mm L2=4.7+-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)At rack position = bb
----------
aa=6deg bb=R1(12.3)mm
----------
a=(150deg)
----------
aa=6deg bb=R1(12.3)mm
----------
a=(150deg)
Information:
2. Remove bolts (1). 3. Disconnect air hose (2) from the cylinder head to the air compressor.4. Remove air compressor inlet tube (3).5. Disconnect the air tube from the inlet manifold to the fuel ratio control. 6. Remove oil inlet tube (4).7. Remove two bolts (5). 8. Remove the bolts that hold the cylinder head to the cylinder block.9. Fasten a hoist to the cylinder head. Carefully remove the head from the block. Weight is 164 lb. (74.4 kg).Install Cylinder Head
1. Install a new, dry cylinder head gasket.2. Fasten a hoist to the cylinder head and put the cylinder head in position on the cylinder block.3. Install the push rods. Put the rocker shaft in position on the engine.
Dowel pins (A) on each end of the rocker shaft assembly must be in alignment with holes (B). If the pins and holes are not in alignment during installation of the rocker shaft assembly, damage to the rocker shaft assembly will be the result.
4. Put 5P3931 Anti-Seize Compound on the threads of cylinder head and rocker shaft bolts. Install the bolts in the following step sequence: 1. Tighten all bolts in number sequence to a torque of 115 lb. ft. (155 N m).2. Tighten all bolts in number sequence to a torque of 185 13 lb. ft. (250 17 N m).3. Tighten all bolts in number sequence (hand turn only) to a torque of 185 13 lb. ft. (250 17 N m) again.4. Tighten all bolts (hand turn only) in letter sequence to a torque of 32 5 lb. ft. (43 7 N m). 5. Make an adjustment to the valves to get a clearance of .015 in. (0.38 mm) for the intake valves and .025 in. (0.64 mm) for the exhaust valves.6. Install the turbocharger oil inlet tube. Install the two bolts that connect the oil outlet tube to the turbocharger.7. Connect the air tube from the fuel ratio control to the inlet manifold.8. Connect the air hose from the air compressor to the cylinder head.9. Install the two bolts removed from the temperature regulator.10. Fill the cooling system with coolant to the correct level.end by:a) install fan driveb) install fuel injection lines
1. Install a new, dry cylinder head gasket.2. Fasten a hoist to the cylinder head and put the cylinder head in position on the cylinder block.3. Install the push rods. Put the rocker shaft in position on the engine.
Dowel pins (A) on each end of the rocker shaft assembly must be in alignment with holes (B). If the pins and holes are not in alignment during installation of the rocker shaft assembly, damage to the rocker shaft assembly will be the result.
4. Put 5P3931 Anti-Seize Compound on the threads of cylinder head and rocker shaft bolts. Install the bolts in the following step sequence: 1. Tighten all bolts in number sequence to a torque of 115 lb. ft. (155 N m).2. Tighten all bolts in number sequence to a torque of 185 13 lb. ft. (250 17 N m).3. Tighten all bolts in number sequence (hand turn only) to a torque of 185 13 lb. ft. (250 17 N m) again.4. Tighten all bolts (hand turn only) in letter sequence to a torque of 32 5 lb. ft. (43 7 N m). 5. Make an adjustment to the valves to get a clearance of .015 in. (0.38 mm) for the intake valves and .025 in. (0.64 mm) for the exhaust valves.6. Install the turbocharger oil inlet tube. Install the two bolts that connect the oil outlet tube to the turbocharger.7. Connect the air tube from the fuel ratio control to the inlet manifold.8. Connect the air hose from the air compressor to the cylinder head.9. Install the two bolts removed from the temperature regulator.10. Fill the cooling system with coolant to the correct level.end by:a) install fan driveb) install fuel injection lines