Information injection-pump assembly
ZEXEL
101401-4392
1014014392
ISUZU
8970613933
8970613933
Rating:
Service parts 101401-4392 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97114-315-1
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
14.
NOZZLE
Cross reference number
ZEXEL
101401-4392
1014014392
ISUZU
8970613933
8970613933
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
134424-1920
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
1-3-4-2
Pre-stroke
mm
3.8
3.75
3.85
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 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
13.2
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
93
91.4
94.6
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
Z
Rack position
9.7+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
14.5
13.2
15.8
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(13.2)
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
93
92
94
Basic
*
Fixing the lever
*
Boost pressure
kPa
62
62
Boost pressure
mmHg
465
465
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.25
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
95.5
91.5
99.5
Fixing the lever
*
Boost pressure
kPa
62
62
Boost pressure
mmHg
465
465
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2-0.6
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
75
71
79
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.
55
55
87
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R2-0.6
Boost pressure
kPa
26.7
25.4
28
Boost pressure
mmHg
200
190
210
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
R2(R1-0.
55)
Boost pressure
kPa
48.7
48.7
48.7
Boost pressure
mmHg
365
365
365
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
3.8
3.3
4.3
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
4
3.5
4.5
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.
(3)Boost compensator stroke: BCL
----------
T1=J03 BCL=0.6+-0.1mm
----------
----------
T1=J03 BCL=0.6+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=42deg+-5deg b=32deg+-3deg
----------
----------
a=42deg+-5deg b=32deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
0000001501 FICD
(A) applied negative pressure
(B) Screw
(c) Nut
1. Set the actuator as described below.
(1)Confirm that there is clearance between the actuator lever and the speed lever.
(2)Loosen the nut (C).
(3)Push in the screw (B).
(4)Apply P1 from the actuator (A) part.
(5)Pull out the screw (B) slowly.
(6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra.
(7)Torque the nut (C) to T1.
(8)Apply P2 several times.
(9)Confirm that the actuator functions normally.
(10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=410r/min Ra=9.75+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=410r/min Ra=9.75+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)Stamping position on the A/T outer rim
(4)At the No 1 cylinder's beginning of injection, align with the aligning mark seen through the bracket's check hole and mark the A/T's bevel C1.
(5)B.T.D.C.: aa
----------
aa=9deg
----------
a=(60deg) b=(85deg)
----------
aa=9deg
----------
a=(60deg) b=(85deg)
Information:
Cold Weather Battery Maintenance
General Maintenance
1. After adding make-up water, charge the battery. The added water could dilute the electrolyte enough without charging to cause freezing and permanent damage to the battery.2. Keep the batteries fully charged either by operating the charging system or by using a battery charger.3. Keep the battery warm when not in use. In an unheated area, the heat from a lighted electric bulb is usually sufficient.
Use only a shop cord with a heavy wire guard around the light bulb.
Do not lay a lighted bulb directly on a battery case; the heat at point of contact could melt the battery case.Do not lay cloth or flammable material in contact with a lighted bulb; charring and/or fire could result.4. Use starting aids as instructed for starting the engine.5. Use booster batteries as required. Connect the batteries as instructed below.6. If a battery is not going to be used for a period of time, be sure the battery is fully charged while stored. Use a battery hydrometer to check the specific gravity of each cell, and use a battery charger to keep the battery charged. See the instructions below.Voltage Test (After Load)
A load test should be made on a battery that discharges very rapidly when in use. To do this apply a resistance of three times the ampere/hour rating of the battery across the battery main terminals. Allow the resistance to discharge the the battery for 15 seconds and immediately test the battery voltage. A 6 volt battery in good condition will test 4.5 volts; a 12 volt battery in good condition will test 9 volts and a 24 volt battery will test 18 volts.Starter
No periodic service is indicated for the electric starter brushes between general reconditioning periods. The brushes should only be inspected after removal of the starter from the engine and removal of the commutator end bearing frame. The electric starter commutator end and drive end bearings are equipped with wicks for lubrication purposes. The wicks should be saturated with oil whenever the electric starter is removed or disassembled.It is suggested that cleaning and reconditioning be entrusted to your authorized dealer.Pinion Clearance Adjustment
Whenever the solenoid is installed, the pinion clearance should be adjusted. The adjustment should be made with the starting motor removed.Bench test and adjust the pinion clearance at installation of solenoid as follows:
CIRCUIT FOR CHECKING AND ADJUSTING PINION CLEARANCE1. Install the solenoid without connector from the MOTOR terminal on solenoid to the motor.2. Connect a battery, of the same voltage as the solenoid, to the terminal marked SW.3. Connect the other side of battery to ground terminal or to solenoid frame.
ADJUSTING PINION CLEARANCE4. MOMENTARILY flash a jumper wire from the solenoid terminal marked MOTOR to the frame or ground terminal. The pinion will shift into cranking position and will remain there until the battery is disconnected.5. Push pinion towards commutator end to eliminate free movement.6. Pinion clearance should be .36 in. (9.14 mm).7. Adjust clearance by removing plug and turning shaft nut.
ADJUSTING PINION
General Maintenance
1. After adding make-up water, charge the battery. The added water could dilute the electrolyte enough without charging to cause freezing and permanent damage to the battery.2. Keep the batteries fully charged either by operating the charging system or by using a battery charger.3. Keep the battery warm when not in use. In an unheated area, the heat from a lighted electric bulb is usually sufficient.
Use only a shop cord with a heavy wire guard around the light bulb.
Do not lay a lighted bulb directly on a battery case; the heat at point of contact could melt the battery case.Do not lay cloth or flammable material in contact with a lighted bulb; charring and/or fire could result.4. Use starting aids as instructed for starting the engine.5. Use booster batteries as required. Connect the batteries as instructed below.6. If a battery is not going to be used for a period of time, be sure the battery is fully charged while stored. Use a battery hydrometer to check the specific gravity of each cell, and use a battery charger to keep the battery charged. See the instructions below.Voltage Test (After Load)
A load test should be made on a battery that discharges very rapidly when in use. To do this apply a resistance of three times the ampere/hour rating of the battery across the battery main terminals. Allow the resistance to discharge the the battery for 15 seconds and immediately test the battery voltage. A 6 volt battery in good condition will test 4.5 volts; a 12 volt battery in good condition will test 9 volts and a 24 volt battery will test 18 volts.Starter
No periodic service is indicated for the electric starter brushes between general reconditioning periods. The brushes should only be inspected after removal of the starter from the engine and removal of the commutator end bearing frame. The electric starter commutator end and drive end bearings are equipped with wicks for lubrication purposes. The wicks should be saturated with oil whenever the electric starter is removed or disassembled.It is suggested that cleaning and reconditioning be entrusted to your authorized dealer.Pinion Clearance Adjustment
Whenever the solenoid is installed, the pinion clearance should be adjusted. The adjustment should be made with the starting motor removed.Bench test and adjust the pinion clearance at installation of solenoid as follows:
CIRCUIT FOR CHECKING AND ADJUSTING PINION CLEARANCE1. Install the solenoid without connector from the MOTOR terminal on solenoid to the motor.2. Connect a battery, of the same voltage as the solenoid, to the terminal marked SW.3. Connect the other side of battery to ground terminal or to solenoid frame.
ADJUSTING PINION CLEARANCE4. MOMENTARILY flash a jumper wire from the solenoid terminal marked MOTOR to the frame or ground terminal. The pinion will shift into cranking position and will remain there until the battery is disconnected.5. Push pinion towards commutator end to eliminate free movement.6. Pinion clearance should be .36 in. (9.14 mm).7. Adjust clearance by removing plug and turning shaft nut.
ADJUSTING PINION