Information injection-pump assembly
ZEXEL
101603-8650
1016038650
ISUZU
8943959791
8943959791
Rating:
Service parts 101603-8650 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94395-511-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101603-8650
1016038650
ISUZU
8943959791
8943959791
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
12.6
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
80
78.4
81.6
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(12.6)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
80
79
81
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(12.6)
Pump speed
r/min
1425
1425
1425
Average injection quantity
mm3/st.
88.5
84.5
92.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.2
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
67.5
64.3
70.7
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1200
Remarks
Measure the actual advance angle.
Measure the actual advance angle.
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
5.5
5
6
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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=K49
----------
----------
T1=K49
----------
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=40deg+-3deg
----------
aa=35mm
----------
a=14deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-5deg b=40deg+-5deg
----------
aa=46.5mm
----------
a=34.5deg+-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=12.6mm
----------
a=(150deg)
----------
aa=6deg bb=12.6mm
----------
a=(150deg)
Information:
Remove Rocker Shafts And Push Rods
start by:a) remove valve covers 1. Remove four bolts (3) that hold elbow (1) to the inlet manifold. Remove elbow (1) and inlet pipe (2) as a unit. 2. Remove bolts (5) that hold the valve cover bases to the cylinder head. Remove valve cover bases (4). It will be necessary to disconnect the wire clips from the inner fuel injection lines for the precombustion chamber engines. 3. Remove inner fuel injection lines (6). Install caps and plugs on all injection line openings. 4. Remove bolts (7) that hold the rocker shafts to the cylinder head.5. Remove rocker shafts (8). 6. Remove push rods (9) from the valve lifters. 7. Remove bridges (10) from the dowels on the cylinder head.Install Rocker Shafts And Push Rods
1. Put clean engine oil on the bridges and dowels. 2. Install the bridges (1) on the dowels. Keep pressure by hand on the bridges and turn the adjustment screw clockwise until contact is made with the valve stem. Turn the screw an extra 20° to 30°. This will make dowel straight in guide and make compensation for gap (slack) in the threads. Hold adjustment screw in this position and tighten locknut to a torque of 22 3 lb.ft. (28 4 N m). 3. Install push rods (2). 4. Put rocker shafts (3) in position on the cylinder head.5. Put clean engine oil on the threads of the bolts that hold the rocker shafts in place. Tighten the bolts first to a torque of 200 20 lb.ft. (270 25 N m). Start with the bolt in the center of the rocker shaft. Tighten bolts again to a torque of 330 15 lb.ft. (450 20 N m). Tighten bolts again by hand to a torque of 330 15 lb.ft. (450 20 N m).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (4). Tighten the fuel line nuts to a torque of 30 5 lb.ft. (40 7 N m) with tool (A) and (B). Connect wire clips to the fuel injection lines for the precombustion chamber engines.7. Make an adjustment to the valves to have a clearance of .015 in. (0.38 mm) for intake and .030 in. (0.76 mm) for the exhaust. Tighten the locknuts to a torque of 22 3 lb.ft. (28 4 N m) and check the valve clearance again. 8. Install valve cover bases (6) on the cylinder head. Install bolts (5) that hold the valve cover bases in place. Tighten the bolts to a torque of 120 24 lb.in. (13.6 2.8 N m). 9. Put clean oil on the O-ring seal on inlet pipe (8). Install inlet pipe (8) into the turbocharger. Make sure the gasket for elbow (7) is in position on the inlet manifold. Install four bolts that hold elbow (7) to the inlet manifold.end by:a) install valve covers
start by:a) remove valve covers 1. Remove four bolts (3) that hold elbow (1) to the inlet manifold. Remove elbow (1) and inlet pipe (2) as a unit. 2. Remove bolts (5) that hold the valve cover bases to the cylinder head. Remove valve cover bases (4). It will be necessary to disconnect the wire clips from the inner fuel injection lines for the precombustion chamber engines. 3. Remove inner fuel injection lines (6). Install caps and plugs on all injection line openings. 4. Remove bolts (7) that hold the rocker shafts to the cylinder head.5. Remove rocker shafts (8). 6. Remove push rods (9) from the valve lifters. 7. Remove bridges (10) from the dowels on the cylinder head.Install Rocker Shafts And Push Rods
1. Put clean engine oil on the bridges and dowels. 2. Install the bridges (1) on the dowels. Keep pressure by hand on the bridges and turn the adjustment screw clockwise until contact is made with the valve stem. Turn the screw an extra 20° to 30°. This will make dowel straight in guide and make compensation for gap (slack) in the threads. Hold adjustment screw in this position and tighten locknut to a torque of 22 3 lb.ft. (28 4 N m). 3. Install push rods (2). 4. Put rocker shafts (3) in position on the cylinder head.5. Put clean engine oil on the threads of the bolts that hold the rocker shafts in place. Tighten the bolts first to a torque of 200 20 lb.ft. (270 25 N m). Start with the bolt in the center of the rocker shaft. Tighten bolts again to a torque of 330 15 lb.ft. (450 20 N m). Tighten bolts again by hand to a torque of 330 15 lb.ft. (450 20 N m).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (4). Tighten the fuel line nuts to a torque of 30 5 lb.ft. (40 7 N m) with tool (A) and (B). Connect wire clips to the fuel injection lines for the precombustion chamber engines.7. Make an adjustment to the valves to have a clearance of .015 in. (0.38 mm) for intake and .030 in. (0.76 mm) for the exhaust. Tighten the locknuts to a torque of 22 3 lb.ft. (28 4 N m) and check the valve clearance again. 8. Install valve cover bases (6) on the cylinder head. Install bolts (5) that hold the valve cover bases in place. Tighten the bolts to a torque of 120 24 lb.in. (13.6 2.8 N m). 9. Put clean oil on the O-ring seal on inlet pipe (8). Install inlet pipe (8) into the turbocharger. Make sure the gasket for elbow (7) is in position on the inlet manifold. Install four bolts that hold elbow (7) to the inlet manifold.end by:a) install valve covers