Information injection-pump assembly
ZEXEL
101402-4131
1014024131
ISUZU
8970209291
8970209291
Rating:
Service parts 101402-4131 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97013-319-1
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-4131
1014024131
ISUZU
8970209291
8970209291
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
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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 injection pump housing must be clean.
1. Disconnect two fuel lines (1) from the fuel transfer pump. 2. Remove two bolts (3) and fuel transfer pump (2).Install Fuel Transfer Pump
1. Put fuel transfer pump (1) in position and install the two bolts that hold it to the fuel pump housing. 2. Connect two lines (2) to the fuel transfer pump.Disassemble Fuel Transfer Pump
start by:a) remove fuel transfer pump 1. Remove bolts (1) that hold transfer pump cover (2) to transfer pump body (5).2. Remove bolts and clamps (4) from the tachometer drive adapter. Remove tachometer drive adapter (3) from the cover. 3. Remove lip type seal (6) from the cover. Remove plug and O-ring seal (7), seat (8), spring (9) and valve (10) from the cover. 4. Remove nut (14) on end of shaft (11) and remove gear (17) and key (12) from the shaft. Remove O-ring seal (13) and the shaft from the body (5).5. Remove idler gear (15) from shaft (16).6. Remove the bearings and the two lip type seals from the body.7. Remove the check valve and shaft (16) from the body.Assemble Fuel Transfer Pump
1. Clean the openings (ports) for the fuel passage in body (3).2. Install shaft (1) and check valve (2) in the body with tooling (A).3. Install smaller bearing (4) in the body with tooling (B). Install the bearing until it is even with the machined surface of the body. 4. Install seal (5) in the body with tooling (C). Install the seal until it is .969 in. (24.6 mm) from the top surface of the body and with the lip toward bearing (4) as shown.5. Install seal (6) in body (3) with tooling (D). Install the seal until it is .563 in. (14.3 mm) from the top surface of the body and with the lip toward the top surface of body (3) as shown. 6. Install the large bearing in body (3) with tooling (E). Install the bearing even with the outside surface of the body. 7. Install the seal in cover (7) with tooling (C). Install the seal with the lip toward the inside of the cover and until it is .750 in. (19.1 mm) below the outside surface of the cover.8. Install the fuel bypass valve, the valve, spring, seal, O-ring seal and plug (14) in the cover. Tighten the plug to a torque of 27 3 lb.ft. (38 4 N m).9. Install shaft (9) in the body. Install gear (13) on the shaft to make an alignment with the gear on the shaft.10. Put 7M7260 Liquid Gasket Material on surface of cover (8). Install the cover on the body.
Do not let liquid gasket material enter the pump.
11. Install the six bolts that hold the cover (7) to the body. Install the O-ring seal to the body. The shaft must turn freely after the bolts that hold the cover in position are tightened.12.