Information injection-pump assembly
ZEXEL
101402-4132
1014024132
ISUZU
8970209292
8970209292
Rating:
Service parts 101402-4132 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
101402-4132
1014024132
ISUZU
8970209292
8970209292
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
A
Rack position
9.6
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
74.7
73.6
75.8
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.6+-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=14 N1=1100r/min N2=700r/min
----------
----------
K=14 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
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----------
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.
----------
----------
----------
----------
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:
start by:a) remove fuel ratio control 1. Remove bolt (4). Remove lever (5) and the rod from the governor.2. Remove lockwire (2). Remove bolts (1) and cover (3) from the governor housing. Check the condition of the gasket under the cover. If the gasket has damage, use a new part for replacement. 3. Remove the bolt from stop collar (6). Remove stop collar (6). Remove the collar and spring from below collar (6). 4. Install tool (A) in the fuel injection pump housing. Make sure the correct end of tool (A) is used. Tool (A) is in position when it is against the shoulder of the groove in the rack. The racks are now in the center (zero) position.5. Remove bolts (8) and governor housing (7). 6. Disconnect fuel lines (11) from the governor plate.7. Remove bolts (10) and governor plate (9). Check the condition of the gasket under the plate. If the gasket has damage, use a new part for replacement. It is possible to remove the governor and governor plate as a unit. The above steps must be followed before the governor can be installed again on the injection pump housing.Install Governor (Earlier)
The driver assembly must be removed from the governor plate before the governor plate is installed in the injection pump housing.
1. Install a new gasket on the injection pump housing. 2. Put governor plate (1) in position on the fuel pump housing. Make sure the dowels in governor plate (1) are in alignment with the holes in the injection pump housing. The racks must be held against the rack stop pin and the governor lever engaged in the groove (slot) in the left hand rack. 3. Install stop (3) in gear (4). Make sure the wide space in stop (3) is in alignment with the wide space on the drive pinion assembly.4. Install drive gear assembly (2). 5. Make an alignment of the holes in gear (4), the stop and drive assembly. Install the pin and ring (5) that hold the unit together. 6. Install the gasket and governor housing (8) on the governor plate.7. Install the spring, collar and stop collar (7). Install the bolt in the collar to hold it.8. Check the governor adjustment. See GOVERNOR ADJUSTMENTS in TESTING AND ADJUSTING.9. Install the gasket and cover (6) on the governor housing. Make sure the dowel in the cover is in alignment with the notch in collar (7). Install the bolts that hold the cover in position. Install a new lockwire.10. Connect the fuel lines to the governor plate.11. Install the lever for the governor control.12. Remove tool (A) from the injection pump housing.end by:a) install fuel ratio control
The driver assembly must be removed from the governor plate before the governor plate is installed in the injection pump housing.
1. Install a new gasket on the injection pump housing. 2. Put governor plate (1) in position on the fuel pump housing. Make sure the dowels in governor plate (1) are in alignment with the holes in the injection pump housing. The racks must be held against the rack stop pin and the governor lever engaged in the groove (slot) in the left hand rack. 3. Install stop (3) in gear (4). Make sure the wide space in stop (3) is in alignment with the wide space on the drive pinion assembly.4. Install drive gear assembly (2). 5. Make an alignment of the holes in gear (4), the stop and drive assembly. Install the pin and ring (5) that hold the unit together. 6. Install the gasket and governor housing (8) on the governor plate.7. Install the spring, collar and stop collar (7). Install the bolt in the collar to hold it.8. Check the governor adjustment. See GOVERNOR ADJUSTMENTS in TESTING AND ADJUSTING.9. Install the gasket and cover (6) on the governor housing. Make sure the dowel in the cover is in alignment with the notch in collar (7). Install the bolts that hold the cover in position. Install a new lockwire.10. Connect the fuel lines to the governor plate.11. Install the lever for the governor control.12. Remove tool (A) from the injection pump housing.end by:a) install fuel ratio control