Information injection-pump assembly
ZEXEL
101402-0731
1014020731
ISUZU
8944206621
8944206621
Rating:
Service parts 101402-0731 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-120-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-0731
1014020731
ISUZU
8944206621
8944206621
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
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
A
Rack position
10
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
81
79.5
82.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
6.7+-0.5
Pump speed
r/min
335
335
335
Average injection quantity
mm3/st.
8.6
7.2
10
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)The torque control spring does not operate.
----------
K=6
----------
----------
K=6
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=1deg+-5deg b=23deg+-5deg
----------
----------
a=1deg+-5deg b=23deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=19deg+-5deg b=53deg+-5deg
----------
----------
a=19deg+-5deg b=53deg+-5deg
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=18deg
----------
a=(90deg)
----------
aa=18deg
----------
a=(90deg)
Information:
Introduction
Do not perform any of the following procedure or order parts until you have read and understand the procedure. The procedure that follows below covers that installation of the new Diesel Exhaust Fluid (DEF) filter.Required Parts
Table 1 below contain the parts needed to complete the installation of the new DEF filter.Note: Only one DEF filter group is required per engine. Use Table 2 to determine which filter is the appropriate filter for each DEF header. Illustration 1 shows the location of the DEF header part number.
Table 1
Item Qty Part Number Part Description
1 1 452-6055 Filter Base As
2 1 453-1604(1) Diesel Exhaust Fluid Filter Gp
3 1 453-1605***#i05999309/d1820e940*** Diesel Exhaust Fluid Filter Gp
4 1 453-1606***#i05999309/d1820e940*** Diesel Exhaust Fluid Filter Gp
5 1 378-3187 Diesel Exhaust Fluid Filter Gp
6 1 423-3251 Connector
7 1 425-0385 Filter As
8 1 391-5262 Gasket
(1) Use Table 2 to choose the correct part that corresponds to the DEF header
Illustration 1 g03745839
(1) Location of DEF header part number
Table 2
DEF Header Part Number Required DEF Filter
434-3241 453-1604
434-3242 453-1605
434-3243 453-1606 Installation Procedure
Illustration 2 g03736523
(1) DEF header
(2) DEF filter
(3) DEF tank
(4) DEF header bolts
Clean the area around DEF header (1). Clear any dirt or debris that could contaminate the DEF tank or lines when removed. Note: If proper cleaning is not performed, DEF pump performance issues or failure may occur.
Disconnect the two DEF lines, two coolant lines, and harness from the DEF header assembly.
Remove the six DEF header screws (4) from the DEF header assembly. Note: Do not discard the screws that secure the DEF header assembly to the DEF tank. The screws will be reused in a later step.
Remove the DEF header assembly. Remove the previous DEF header gasket and discard.
Illustration 3 g03736534
(5) 452-6055 Filter Base As
Install filter base assembly (5) onto the DEF header assembly. Note: Each half of the adapter has two small locking tabs that secure to the bottom side of the DEF header assembly.
Remove the previous 425-0385 Filter As located at the bottom of the DEF pick-up tube.
Install the new 425-0385 Filter As onto the DEF header assembly.
Illustration 4 g03736545
(6) Band clamp
Install the correct DEF filter onto the DEF header adapter and secure using band clamp (6) that is supplied. Torque the band clamp to 4.5 0.7 N m (40 6 lb in).
Install the DEF header assembly back into the DEF tank. Secure the DEF header to the DEF tank using the six screws previously removed in Step 3. Torque the six screws to 5 1 N m (44 9 lb in).
Reconnect the harness, coolant lines, and DEF lines to the DEF header.
Illustration 5 g03736566
(7) DEF pump inlet filter fitting
(8) Main DEF pump filter
Replace DEF pump inlet filter fitting (7) and main DEF pump filter (8). Refer to Disassembly and Assembly, UENR0132, "Diesel Exhaust Fluid Filter - Remove and Install" for the replacement procedure.
Do not perform any of the following procedure or order parts until you have read and understand the procedure. The procedure that follows below covers that installation of the new Diesel Exhaust Fluid (DEF) filter.Required Parts
Table 1 below contain the parts needed to complete the installation of the new DEF filter.Note: Only one DEF filter group is required per engine. Use Table 2 to determine which filter is the appropriate filter for each DEF header. Illustration 1 shows the location of the DEF header part number.
Table 1
Item Qty Part Number Part Description
1 1 452-6055 Filter Base As
2 1 453-1604(1) Diesel Exhaust Fluid Filter Gp
3 1 453-1605***#i05999309/d1820e940*** Diesel Exhaust Fluid Filter Gp
4 1 453-1606***#i05999309/d1820e940*** Diesel Exhaust Fluid Filter Gp
5 1 378-3187 Diesel Exhaust Fluid Filter Gp
6 1 423-3251 Connector
7 1 425-0385 Filter As
8 1 391-5262 Gasket
(1) Use Table 2 to choose the correct part that corresponds to the DEF header
Illustration 1 g03745839
(1) Location of DEF header part number
Table 2
DEF Header Part Number Required DEF Filter
434-3241 453-1604
434-3242 453-1605
434-3243 453-1606 Installation Procedure
Illustration 2 g03736523
(1) DEF header
(2) DEF filter
(3) DEF tank
(4) DEF header bolts
Clean the area around DEF header (1). Clear any dirt or debris that could contaminate the DEF tank or lines when removed. Note: If proper cleaning is not performed, DEF pump performance issues or failure may occur.
Disconnect the two DEF lines, two coolant lines, and harness from the DEF header assembly.
Remove the six DEF header screws (4) from the DEF header assembly. Note: Do not discard the screws that secure the DEF header assembly to the DEF tank. The screws will be reused in a later step.
Remove the DEF header assembly. Remove the previous DEF header gasket and discard.
Illustration 3 g03736534
(5) 452-6055 Filter Base As
Install filter base assembly (5) onto the DEF header assembly. Note: Each half of the adapter has two small locking tabs that secure to the bottom side of the DEF header assembly.
Remove the previous 425-0385 Filter As located at the bottom of the DEF pick-up tube.
Install the new 425-0385 Filter As onto the DEF header assembly.
Illustration 4 g03736545
(6) Band clamp
Install the correct DEF filter onto the DEF header adapter and secure using band clamp (6) that is supplied. Torque the band clamp to 4.5 0.7 N m (40 6 lb in).
Install the DEF header assembly back into the DEF tank. Secure the DEF header to the DEF tank using the six screws previously removed in Step 3. Torque the six screws to 5 1 N m (44 9 lb in).
Reconnect the harness, coolant lines, and DEF lines to the DEF header.
Illustration 5 g03736566
(7) DEF pump inlet filter fitting
(8) Main DEF pump filter
Replace DEF pump inlet filter fitting (7) and main DEF pump filter (8). Refer to Disassembly and Assembly, UENR0132, "Diesel Exhaust Fluid Filter - Remove and Install" for the replacement procedure.