Information injection-pump assembly
ZEXEL
104303-2140
1043032140
ISUZU
5156013380
5156013380
Rating:
Cross reference number
ZEXEL
104303-2140
1043032140
ISUZU
5156013380
5156013380
Zexel num
Bosch num
Firm num
Name
104303-2140
5156013380 ISUZU
INJECTION-PUMP ASSEMBLY
3AF1 * K
3AF1 * K
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
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-2
Pre-stroke
mm
2.1
2.05
2.15
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 2
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
28.4
27.4
29.4
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.1+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
6.5
5.5
7.5
Max. variation between cylinders
%
0
-14
14
Fixing the lever
*
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
C
Rack position
13+1
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
37
37
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
9.2
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
25.9
23.9
27.9
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Rack difference between N = N1 and N = N2
(2)Set the idle spring.
(3)Main spring setting
----------
N1=700r/min N2=1300r/min
----------
----------
N1=700r/min N2=1300r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=36deg+-3deg b=33deg+-6deg
----------
----------
a=36deg+-3deg b=33deg+-6deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=18deg+-5deg b=(38deg)
----------
----------
a=18deg+-5deg b=(38deg)
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '00' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(110deg)
----------
aa=16deg
----------
a=(110deg)
Information:
Installation of Nozzles, Ether Supply Tubes and Connectors
1. If the machine does not already have an ether aid starting system, remove the plugs from turbocharger outlet adapters on the engine. 2. Install a 3B6768 Bushing with a 7X1078 Nozzle Assembly (2) where each plug was removed. If machine was equipped with an ether aid starting system. Discard old nozzles and install new nozzles.3. When installing each nozzle assembly (2), the indicator mark at location (J) must be at the top as shown. Tighten the nozzle to a torque of 2.8 N m (25 lb in).
Top View
Side View DO NOT overtighten tube assembly fittings. Over tightening can cause damage to tubing.4. Install 8X0912 Tube (9) in the front nozzle and 8W8174 Tube (7) in the rear nozzle as shown. Connect tubes (7) and (9) to 8C9006 Tee (8) using two 5P6314 Sleeves and 5P6313 Nuts.5. Put 8W8172 Tube (5) in position along the cylinder block and connect it to 8C9006 Tee (8) as shown using 5P6314 Sleeve and 5P6313 Nut.6. Connect one end of 8W8171 Tube (10) to elbow (11) on the bottom of the shuttle valve using a 5P6313 Nut and 5P6314 Sleeve. Fasten the tube to the frame cross tube using 6V2686 Clip (6) as shown.7. Connect one end of 7N0140 Tube Assembly (4) to the end of 8W8171 Tube (10) and connect the other end to the free end of 8W8172 Tube (5).8. Fasten the ether tubing assemblies, using three 6V2686 Clips (3) with existing bolts, on engine block and right regulator housing as shown.Installation of Ether Cylinders
1. Turn the disconnect switch to the ON position and put the start switch key in the OFF position. Make sure the two lamps on the console and the two yellow LEDs on the ECU are flashing.If they are flashing, it indicates that the control is functioning and recognizes that no ether cylinders are installed.2. Inspect the two digit, seven segment LED display on the ECU. It must read "OO". This in an indication that there are no faults.If the display does not read "OO", refer to the Service Manual for a troubleshooting procedure of the system. 3. Remove protective caps (1) and (3) from 9X7137 Ether Solenoid Valves (2) and (4). Install a new 9X7138 Filter Assembly in each solenoid valve inlet.4. Install a 9X0147 Collar on the neck of each new 7X1062 Ether Cylinder.5. Remove the protective plug from the end of the new FULL ether cylinder, then install the new ether cylinder on ether solenoid valve (2). The ether valve assembly at left location (C) is referred to as Ether Assembly No. 1. The ether valve assembly at right location (D) is referred to as Ether Assembly No. 2.Make sure that the dash mounted ETHER OUT warning lamp No. 1 and the ETHER OUT warning LED on the ECU are OFF. Repeat this procedure for installation of
1. If the machine does not already have an ether aid starting system, remove the plugs from turbocharger outlet adapters on the engine. 2. Install a 3B6768 Bushing with a 7X1078 Nozzle Assembly (2) where each plug was removed. If machine was equipped with an ether aid starting system. Discard old nozzles and install new nozzles.3. When installing each nozzle assembly (2), the indicator mark at location (J) must be at the top as shown. Tighten the nozzle to a torque of 2.8 N m (25 lb in).
Top View
Side View DO NOT overtighten tube assembly fittings. Over tightening can cause damage to tubing.4. Install 8X0912 Tube (9) in the front nozzle and 8W8174 Tube (7) in the rear nozzle as shown. Connect tubes (7) and (9) to 8C9006 Tee (8) using two 5P6314 Sleeves and 5P6313 Nuts.5. Put 8W8172 Tube (5) in position along the cylinder block and connect it to 8C9006 Tee (8) as shown using 5P6314 Sleeve and 5P6313 Nut.6. Connect one end of 8W8171 Tube (10) to elbow (11) on the bottom of the shuttle valve using a 5P6313 Nut and 5P6314 Sleeve. Fasten the tube to the frame cross tube using 6V2686 Clip (6) as shown.7. Connect one end of 7N0140 Tube Assembly (4) to the end of 8W8171 Tube (10) and connect the other end to the free end of 8W8172 Tube (5).8. Fasten the ether tubing assemblies, using three 6V2686 Clips (3) with existing bolts, on engine block and right regulator housing as shown.Installation of Ether Cylinders
1. Turn the disconnect switch to the ON position and put the start switch key in the OFF position. Make sure the two lamps on the console and the two yellow LEDs on the ECU are flashing.If they are flashing, it indicates that the control is functioning and recognizes that no ether cylinders are installed.2. Inspect the two digit, seven segment LED display on the ECU. It must read "OO". This in an indication that there are no faults.If the display does not read "OO", refer to the Service Manual for a troubleshooting procedure of the system. 3. Remove protective caps (1) and (3) from 9X7137 Ether Solenoid Valves (2) and (4). Install a new 9X7138 Filter Assembly in each solenoid valve inlet.4. Install a 9X0147 Collar on the neck of each new 7X1062 Ether Cylinder.5. Remove the protective plug from the end of the new FULL ether cylinder, then install the new ether cylinder on ether solenoid valve (2). The ether valve assembly at left location (C) is referred to as Ether Assembly No. 1. The ether valve assembly at right location (D) is referred to as Ether Assembly No. 2.Make sure that the dash mounted ETHER OUT warning lamp No. 1 and the ETHER OUT warning LED on the ECU are OFF. Repeat this procedure for installation of
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Isuzu
104303-2140
5156013380
INJECTION-PUMP ASSEMBLY
3AF1
3AF1