Information injection-pump assembly
ZEXEL
101402-4130
1014024130
ISUZU
8970209290
8970209290
Rating:
Service parts 101402-4130 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97016-146-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-4130
1014024130
ISUZU
8970209290
8970209290
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
9.8
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
76.9
75.8
78
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.7+-0.5
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
8.8
7.4
10.2
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Set idle sub-spring
(3)Main spring setting
(4)Rack difference between N = N1 and N = N2
----------
K=7 N1=1100r/min N2=700r/min
----------
----------
K=7 N1=1100r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
D:Dead point
S:Stop
----------
----------
a=(18deg)+-5deg b=(17deg)+-5deg c=(15deg)+-5deg d=13deg+-3deg
----------
----------
a=(18deg)+-5deg b=(17deg)+-5deg c=(15deg)+-5deg d=13deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=6deg+-5deg b=46deg+-5deg
----------
----------
a=6deg+-5deg b=46deg+-5deg
0000001501 LEVER
1. Variable lever adjustment
(1)Fix lever B in the idle position using the bolts C and D.
(2)Temporarily fix lever A in center of long hole.
(3)Set the dead point position temporarily and measure the lever angle.
(4)After idle adjustment, loosen the full side stopper bolt D.
(5)Move lever A in full speed direction.
(6)Fix the bolt D at the full speed position.
(7)Fix lever A using bolt E.
(8)(G) Lock using bolt.
(9)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
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----------
----------
----------
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:
Before any service work is done on the fuel system, the outer surface of the fuel injection pump housing must be clean.
1. Cut governor safety wire (1).2. Disconnect line (3) from the fuel ratio control.3. Remove the two bolts and fuel ratio control (2).Install Fuel Ratio Control
1. Put fuel ratio control in position. Make an alignment of opening (slot) (2) with the plunger in the fuel ratio control.2. Use 9S3263 Thread Lock and install the two bolts that hold fuel ratio control (1) to the governor plate. 3. Connect line (3) to the fuel ratio control.4. Install a new lockwire and seal. See FUEL RACK SETTING in TESTING AND ADJUSTING.
The lockwire and seal must be installed in order to validate the warranty.
Disassemble Fuel Ratio Control
start by:a) remove fuel ratio control 1. Remove two bolts (1) and cover (2). 2. Remove valve assembly (3).3. Remove seal (4) and the O-ring seal from the valve assembly.4. Remove retainer (5) and two springs (6). 5. Remove the three bolts from the cover. Remove cover (12) and gasket (11).6. Remove valve (13), diaphragm, (8), retainer (9) and spring (10).7. Remove pin (14) from valve (13).8. Remove cover (7) from the valve.Assemble Fuel Ratio Control
1. Put clean SAE 30 oil on the seal. Install seal (1) in cover (2) with the lip of the seal toward the inside of the cover. 2. Install valve (3) in cover (2).3. Install the pin that holds the cover on the valve. 4. Install the spring and the retainer in cover (6).5. Install diaphragm (5) on the valve assembly (4) and in the cover.6. Install cover (8). Install three bolts (7) that hold the cover in position. 7. Put clean SAE 30 oil on the seal and the ring seal. Install seals (11) on valve.8. Install two springs (12), retainer (13) and valve assembly (10).9. Install housing (9) and the bolts.
Correct adjustment must be made to fuel ratio control before installation. See ADJUSTMENT OF AIR FUEL RATIO CONTROL in TESTING AND ADJUSTING.
end by:a) install fuel ratio control