Information injection-pump assembly
ZEXEL
101603-8600
1016038600
ISUZU
8943959201
8943959201
Rating:
Service parts 101603-8600 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94395-923-2
12.
Open Pre:MPa(Kqf/cm2)
22.1{225}
15.
NOZZLE SET
Include in #1:
101603-8600
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-5470
as _
Cross reference number
ZEXEL
101603-8600
1016038600
ISUZU
8943959201
8943959201
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
11.7
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
82
80.4
83.6
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.
10
8.7
11.3
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(11.7)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
82
81
83
Basic
*
Fixing the lever
*
Boost pressure
kPa
40
40
Boost pressure
mmHg
300
300
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.35
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
87.5
84.3
90.7
Fixing the lever
*
Boost pressure
kPa
40
40
Boost pressure
mmHg
300
300
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.8
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
68.5
65.3
71.7
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.
105
105
137
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
850
850
850
Rack position
R1-0.8
Boost pressure
kPa
12
10.7
13.3
Boost pressure
mmHg
90
80
100
Boost compensator adjustment_02
Pump speed
r/min
850
850
850
Rack position
R1(11.7)
Boost pressure
kPa
26.7
20
33.4
Boost pressure
mmHg
200
150
250
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)Boost compensator stroke: BCL
(4)Adjust so that the boost compensator pushrod protrusion R = Ra at 0 boost.
----------
T1=K57 BCL=0.8+-0.1mm Ra=12+-0.5mm
----------
----------
T1=K57 BCL=0.8+-0.1mm Ra=12+-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt setting
----------
aa=35mm
----------
a=12deg+-5deg b=35deg+-3deg
----------
aa=35mm
----------
a=12deg+-5deg b=35deg+-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=9deg
----------
a=(150deg)
----------
aa=9deg
----------
a=(150deg)
Information:
start by:a) separation of governor from fuel injection pump housing 1. Remove the ring (3) and pin (1) that hold seat (2). 2. Remove seat (2), bolt (4), washers (6) and spring (5).3. Remove the sleeve and bearing assembly from the cylinder and weight assemblies. 4. Remove ring (7) from sleeve (8).5. Remove bearing (9) and washers (10) from sleeve (8). 6. Remove valve (12) from piston (11). 7. Remove ring (15) that holds the weight assembly to cylinder (16).8. Remove weight assembly (13) from the cylinder.9. Remove piston (11) and sleeve (14) from the cylinder. Remove the O-ring seal from sleeve (14). 10. Remove speed limiter plug (20), spring and plunger from the governor housing (19).11. Remove torque spring assembly (17). 12. Remove bolt (21) and lock that hold lever (22) to shaft (18).13. Remove lever (22) and shaft from the housing.14. Remove the seal from housing (19).15. Remove the bearings and plug from the housing with tooling (A). 16. Remove two bolts (23), lock, lever arm (26) and shaft (25) from idle screw housing (24).17. Remove the two seals, bearings and plug from housing (24) with tooling (A).Assemble Governor
1. Use tooling (A) to install inner seal (3) in idle screw housing (2). Install seal (3) so the lip of the seal is toward bearing (4). Put clean engine oil on the lips of the seals.2. Use tooling (A) to install bearing (1) and the outer seal. Install the outer seal with the lip of the seal toward the outside. Install bearing (4). 3. Install bearing (6) in governor housing (8) to dimension (Y) or .897 .010 in. (22.97 0.25 mm) with tooling (A). Install bearing (5) in the governor housing to dimension (X) or 2.385 .005 in. (60.58 0.13 mm) from bearing (6). Install plug (7) in the governor housing. 4. Use tooling (A) to install the seal in governor housing (8). Install the seal with the lip of the seal toward the inside.5. Install torque spring assembly (9) on the governor housing. Install the lock and bolts that hold it. See RACK SETTING INFORMATION for the correct adjustment of the torque spring assembly. 6. Put lever assembly (11) in position in the governor housing. Install shaft (10) in the housing through the lever. Install the lock and bolt that hold the lever to the shaft. 7. Install speed limiter plunger (14), spring (13) and plug (12) in the governor housing. 8. Install O-ring seal (17) on sleeve (18).9. Install piston (16) and the sleeve in cylinder (15). 10. Put weight assembly (19) on cylinder (15). Install the ring that holds the weight assembly on the cylinder. 11. Install valve (21) in piston (16).12. Install bearing and washers (22) on sleeve (20). Install the ring that holds the washers and bearing on the sleeve.13. Install the sleeve assembly on valve (21). 14. Install bolt (23) in seat (24). Install the washers and spring in the seat.15. Put the seat in position on
1. Use tooling (A) to install inner seal (3) in idle screw housing (2). Install seal (3) so the lip of the seal is toward bearing (4). Put clean engine oil on the lips of the seals.2. Use tooling (A) to install bearing (1) and the outer seal. Install the outer seal with the lip of the seal toward the outside. Install bearing (4). 3. Install bearing (6) in governor housing (8) to dimension (Y) or .897 .010 in. (22.97 0.25 mm) with tooling (A). Install bearing (5) in the governor housing to dimension (X) or 2.385 .005 in. (60.58 0.13 mm) from bearing (6). Install plug (7) in the governor housing. 4. Use tooling (A) to install the seal in governor housing (8). Install the seal with the lip of the seal toward the inside.5. Install torque spring assembly (9) on the governor housing. Install the lock and bolts that hold it. See RACK SETTING INFORMATION for the correct adjustment of the torque spring assembly. 6. Put lever assembly (11) in position in the governor housing. Install shaft (10) in the housing through the lever. Install the lock and bolt that hold the lever to the shaft. 7. Install speed limiter plunger (14), spring (13) and plug (12) in the governor housing. 8. Install O-ring seal (17) on sleeve (18).9. Install piston (16) and the sleeve in cylinder (15). 10. Put weight assembly (19) on cylinder (15). Install the ring that holds the weight assembly on the cylinder. 11. Install valve (21) in piston (16).12. Install bearing and washers (22) on sleeve (20). Install the ring that holds the washers and bearing on the sleeve.13. Install the sleeve assembly on valve (21). 14. Install bolt (23) in seat (24). Install the washers and spring in the seat.15. Put the seat in position on