Information injection-pump assembly
ZEXEL
101603-8830
1016038830
ISUZU
8943900810
8943900810
Rating:
Service parts 101603-8830 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94395-498-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101603-8830
1016038830
ISUZU
8943900810
8943900810
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
105780-8260
Bosch type code
9 430 610 133
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
18
Opening pressure
kgf/cm2
184
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
3.95
4.05
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
11.5
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
87.5
85.9
89.1
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
Z
Rack position
9.6+-0.5
Pump speed
r/min
240
240
240
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
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.5)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
87.5
86.5
88.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1
Pump speed
r/min
1425
1425
1425
Average injection quantity
mm3/st.
98
94
102
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.65
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
96.5
92.5
100.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
130
130
138
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
905--
Advance angle
deg.
0
0
0
Load
0/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
855
Advance angle
deg.
0.3
Load
0/4
Timer adjustment_03
Pump speed
r/min
(900)
Advance angle
deg.
0
0
0
Load
4/4
Remarks
Start
Start
Timer adjustment_04
Pump speed
r/min
1425
Advance angle
deg.
5.5
5
6
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)RACK LIMIT
----------
T1=K97
----------
----------
T1=K97
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=11deg+-5deg b=39deg+-3deg
----------
aa=35mm
----------
a=11deg+-5deg b=39deg+-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=7deg
----------
a=(150deg)
----------
aa=7deg
----------
a=(150deg)
Information:
TIMING PIN HOLE PLUG
1. Plug.3. Rotate the crankshaft CLOCKWISE (as viewed from front of engine) until the timing pin drops into the timing slot in the fuel injection pump camshaft.4. Install the timing plate (4) on the front of the engine and put bolt (5) through the timing plate and thread it into the gear.
If bolt (5) will not thread into the timing gear, the bolts (2) and the tachometer drive assembly (3) MUST be removed before the crankshaft is rotated farther for the alignment of bolt (5) with the timing hole in the timing gear.
TIMING PLATE INSTALLED
2. Bolts (three). 3. Tachometer drive assembly. 4. 5P950 Timing plate. 5. Bolt.5. Remove bolts (2) and the tachometer drive assembly (3).
TACHOMETER DRIVE ASSEMBLY REMOVED
6. Gear.6. Remove gear (6) from the fuel injection pump camshaft.Install Gear On Fuel Injection Pump Camshaft
1. Install gear (6) on the fuel injection pump camshaft with the holes in the position shown and the part number facing out. To be able to advance the timing adjustment, at a future time, without removing the front cover, position gear (6) in the direction of the arrow so the bolt holes in the fuel injection pump camshaft are off center as shown. The bolts must thread freely into the holes in the fuel injection pump camshaft.
GEAR INSTALLED
6. Gear.2. Install tachometer drive assembly (3) and tighten finger tight.3. Install bolts (2) and tighten the bolts to 32 5 lb. ft. (4.4 0.7 mkg). Tighten tachometer drive assembly (3) to 50 10 lb.ft. (6.9 1.4 mkg).4. Remove bolt (5) and timing plate (4).
TACHOMETER DRIVE ASSEMBLY INSTALLED
2. Bolts (three). 3. Tachometer drive assembly. 4. 5P950 Timing plate. 5. Bolt.5. Remove the timing pin from the slot in the fuel injection pump camshaft and install the plug in the hole.6. Install the timing gear (front) cover.