Information injection-pump assembly
ZEXEL
101401-4420
1014014420
ISUZU
8970857010
8970857010
Rating:
Service parts 101401-4420 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-142-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-4420
1014014420
ISUZU
8970857010
8970857010
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.4
3.35
3.45
Beginning of injection position
Drive side NO.1
Drive 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
11.6
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
72.1
70.5
73.7
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
325
325
325
Average injection quantity
mm3/st.
12.1
10.8
13.4
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(11.6)
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
72.1
71.1
73.1
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.2
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
82.6
79.4
85.8
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.1
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
53.6
49.6
57.6
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
(R1+0.1)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
76.1
72.9
79.3
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
116
116
124
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1000+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1600
Advance angle
deg.
2
1.5
2.5
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=C52
----------
----------
T1=C52
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=3.5deg+-5deg b=27deg+-3deg
----------
----------
a=3.5deg+-5deg b=27deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=45deg+-5deg b=40deg+-5deg
----------
----------
a=45deg+-5deg b=40deg+-5deg
0000001501 ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
(D) Cover
1. Aneroid compensator unit adjustment
(1)Select the push rod 2 to obtain L2.
(2)Screw in (A) to obtain L1.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
(3)As there is hysterisis, measure when the absolute pressure drops.
(4)Hysterisis must not exceed rack position = h1.
----------
N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(11.6)mm Rb=(R1-0.15)mm Pa=79.4+-2.7kPa(596+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=72.1+-1cm3/1000st Q2=69.8+-1.6cm3/1000st
----------
N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(11.6)mm Rb=(R1-0.15)mm Pa=79.4+-2.7kPa(596+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=72.1+-1cm3/1000st Q2=69.8+-1.6cm3/1000st
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=13deg
----------
a=(100deg)
----------
aa=13deg
----------
a=(100deg)
Information:
Filters and Pump Housing
1. Open the bleed valve on the pump housing. 2. Unscrew the hand priming pump plunger until it can be pulled out by hand. 3. Move the plunger in and out until fuel flows, free of air bubbles, from the bleed valve. 4. Close the bleed valve. 5. Push the plunger in and tighten by hand.6. Start the engine and check for leaks.Injection Pumps and Lines
The injection pumps and high pressure lines must be primed if the engine will not start, or runs rough, after priming the filters and pump housing.Each injection pump has a reverse flow check valve. These cannot be opened with hand priming pump pressure. Use the following procedure to prime the injection pumps and lines.
The fuel injection nozzles can be permanently damaged by twisting if only one wrench is used to loosen or tighten the fuel line nuts. Use one wrench to hold the nozzle and another to loosen the nut.
1. Loosen each of the fuel line nuts at the cylinder head end.2. Crank the engine with the starting motor until fuel flows, free of air bubbles, from each of the injection lines. Stop cranking the engine.3. Tighten each of the fuel line nuts to a torque of 41 + 7 N m (30 + 5 lb. ft.). Use a second wrench on the nozzle to prevent damage to it.4. Start the engine and check for leaks.
1. Open the bleed valve on the pump housing. 2. Unscrew the hand priming pump plunger until it can be pulled out by hand. 3. Move the plunger in and out until fuel flows, free of air bubbles, from the bleed valve. 4. Close the bleed valve. 5. Push the plunger in and tighten by hand.6. Start the engine and check for leaks.Injection Pumps and Lines
The injection pumps and high pressure lines must be primed if the engine will not start, or runs rough, after priming the filters and pump housing.Each injection pump has a reverse flow check valve. These cannot be opened with hand priming pump pressure. Use the following procedure to prime the injection pumps and lines.
The fuel injection nozzles can be permanently damaged by twisting if only one wrench is used to loosen or tighten the fuel line nuts. Use one wrench to hold the nozzle and another to loosen the nut.
1. Loosen each of the fuel line nuts at the cylinder head end.2. Crank the engine with the starting motor until fuel flows, free of air bubbles, from each of the injection lines. Stop cranking the engine.3. Tighten each of the fuel line nuts to a torque of 41 + 7 N m (30 + 5 lb. ft.). Use a second wrench on the nozzle to prevent damage to it.4. Start the engine and check for leaks.