Information injection-pump assembly
ZEXEL
101603-8351
1016038351
ISUZU
8943953271
8943953271
Rating:
Service parts 101603-8351 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
Include in #1:
101603-8351
as INJECTION-PUMP ASSEMBLY
Include in #2:
104134-1010
as _
Cross reference number
ZEXEL
101603-8351
1016038351
ISUZU
8943953271
8943953271
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
13
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
86.5
84.9
88.1
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
-
Rack position
9.6+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
9.4
8.1
10.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
86.5
85.5
87.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.15
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
95.5
92.3
98.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.25
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
77.5
74.3
80.7
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=K09
----------
----------
T1=K09
----------
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=5deg+-5deg b=40deg+-3deg
----------
aa=43mm
----------
a=5deg+-5deg b=40deg+-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=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131153-9020 ST=A769 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(13)mm
----------
a=(150deg)
----------
aa=6deg bb=R1(13)mm
----------
a=(150deg)
Information:
start by:a) remove pistons1. Check to be sure that all coolant has been removed from the cylinder block.2. Put a cover over the crankshaft journals before liners are removed. 3. Install tool (A) and remove the cylinder liners. 4. Remove filler band (1) and O-ring seals (2) from the cylinder liners.Install Cylinder Liners
1. Clean the cylinder liners and cylinder block. 2. Install the liners (1) in the cylinder block without the O-ring seals and filler bands. See CYLINDER LINER PROJECTION in TESTING AND ADJUSTING. 3. Install tooling (A) and two 5/8" - 11 NC bolts 5 1/2 in. long. Tighten the bolts evenly to 50 lb.ft. (70 N m).4. Check the liner projection with tool (B) at four locations around the liner.5. Liner projection must be .0020 to .0056 in. (0.051 to 0.142 mm). Measurements on the same liner must not be different by more than .002 in. (0.05 mm). Average measurement between liners next to each other must not be different by more than .002 in. (0.05 mm). The maximum permissible difference between average projection of all cylinder liners under one cylinder head is .004 in. (0.10 mm). The liner projection can change if the liner is turned in the bore. 6. If the liner projection is not .0020 to .0056 in. (0.051 to 0.142 mm), check the thickness of the liner flange (2) and the depth of the liner bore in the cylinder block. The thickness of the liner flange (2) must be .4048 .0008 in. (10.282 0.020 mm).7. The depth of the liner bore in the cylinder block must be .401 .001 in. (10.19 0.03 mm). If the liner bore in the block is worn and the measurement is not correct, the liner bore can be corrected with a cylinder block counterboring tool. See SPECIAL INSTRUCTIONS, FORM FM055228.8. Put a mark on the liner and cylinder block so the liner can be installed in the same position from which it was removed. 9. Install new O-ring seals (4) on the cylinder liners. Put liquid soap on the O-ring seals and in the bases in the cylinder block.
The liners must be installed in the cylinder block immediately after filler band (3) is installed. Make sure the marks on the liners and the cylinder block are in alignment when the cylinder liners are installed.
10. Put (dip) the filler band completely in clean SAE 30 oil and install it on the liner immediately.11. Install the liner in the cylinder block immediately with tooling (C).end by:a) install pistons
1. Clean the cylinder liners and cylinder block. 2. Install the liners (1) in the cylinder block without the O-ring seals and filler bands. See CYLINDER LINER PROJECTION in TESTING AND ADJUSTING. 3. Install tooling (A) and two 5/8" - 11 NC bolts 5 1/2 in. long. Tighten the bolts evenly to 50 lb.ft. (70 N m).4. Check the liner projection with tool (B) at four locations around the liner.5. Liner projection must be .0020 to .0056 in. (0.051 to 0.142 mm). Measurements on the same liner must not be different by more than .002 in. (0.05 mm). Average measurement between liners next to each other must not be different by more than .002 in. (0.05 mm). The maximum permissible difference between average projection of all cylinder liners under one cylinder head is .004 in. (0.10 mm). The liner projection can change if the liner is turned in the bore. 6. If the liner projection is not .0020 to .0056 in. (0.051 to 0.142 mm), check the thickness of the liner flange (2) and the depth of the liner bore in the cylinder block. The thickness of the liner flange (2) must be .4048 .0008 in. (10.282 0.020 mm).7. The depth of the liner bore in the cylinder block must be .401 .001 in. (10.19 0.03 mm). If the liner bore in the block is worn and the measurement is not correct, the liner bore can be corrected with a cylinder block counterboring tool. See SPECIAL INSTRUCTIONS, FORM FM055228.8. Put a mark on the liner and cylinder block so the liner can be installed in the same position from which it was removed. 9. Install new O-ring seals (4) on the cylinder liners. Put liquid soap on the O-ring seals and in the bases in the cylinder block.
The liners must be installed in the cylinder block immediately after filler band (3) is installed. Make sure the marks on the liners and the cylinder block are in alignment when the cylinder liners are installed.
10. Put (dip) the filler band completely in clean SAE 30 oil and install it on the liner immediately.11. Install the liner in the cylinder block immediately with tooling (C).end by:a) install pistons