Information injection-pump assembly
ZEXEL
101603-8660
1016038660
ISUZU
8943959801
8943959801
Rating:
Service parts 101603-8660 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
101603-8660
1016038660
ISUZU
8943959801
8943959801
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%
----------
0000001601 AIR CYLINDER
1. (1) Set the speed lever to idle.
(2)Screw in air cylinder (A)
(3)Set the clearance from the speed lever (B) at approximately L.
----------
L=1mm
----------
----------
L=1mm
----------
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:
1. Remove oil supply tube (3), suction bell (2) and suction bell tube (1). 2. Remove bolts (4) that hold the oil pump to the cylinder block and remove oil pump (5).Install Oil Pump
1. Put oil pump (3) in position on the engine. Install the bolts that hold the oil pump to the cylinder block.2. Put clean oil on the O-ring seals of the tubes.3. Install suction bell tube (2), suction bell and oil supply tube (1).end by:a) install oil panDisassemble Oil Pump
start by:a) remove oil pump1. Remove the bolt and washer that hold the gear on the shaft. 2. Use tooling (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve.4. Remove the spring and bypass valve.5. Remove cover (2) from the pump body. 6. Use tooling (B) and remove the bearings from the cover. 7. Remove gears (5) from pump body (4).8. Use tooling (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use tooling (A) to install the bearings in the pump body. Install the bearings so the split in the bearings is 30° 15° from the center line of the oil pump outlet passage (2). 2. Install idler gear (1) and drive gear (3) in the oil pump body. Put clean engine oil on the bearings and the gears. 3. Use tooling (A) and install the bearings in cover (4). Install the bearings so the split in the bearings is 30° 15° from the center line of the bearing bores toward oil pump outlet passage (2).4. Install bypass valve (5), spring (6) and the retainer.5. Install the key on the shaft. 6. Install gear (7) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.end by:a) install oil pump
1. Put oil pump (3) in position on the engine. Install the bolts that hold the oil pump to the cylinder block.2. Put clean oil on the O-ring seals of the tubes.3. Install suction bell tube (2), suction bell and oil supply tube (1).end by:a) install oil panDisassemble Oil Pump
start by:a) remove oil pump1. Remove the bolt and washer that hold the gear on the shaft. 2. Use tooling (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve.4. Remove the spring and bypass valve.5. Remove cover (2) from the pump body. 6. Use tooling (B) and remove the bearings from the cover. 7. Remove gears (5) from pump body (4).8. Use tooling (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use tooling (A) to install the bearings in the pump body. Install the bearings so the split in the bearings is 30° 15° from the center line of the oil pump outlet passage (2). 2. Install idler gear (1) and drive gear (3) in the oil pump body. Put clean engine oil on the bearings and the gears. 3. Use tooling (A) and install the bearings in cover (4). Install the bearings so the split in the bearings is 30° 15° from the center line of the bearing bores toward oil pump outlet passage (2).4. Install bypass valve (5), spring (6) and the retainer.5. Install the key on the shaft. 6. Install gear (7) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.end by:a) install oil pump