Information injection-pump assembly
ZEXEL
101402-4160
1014024160
ISUZU
8970200410
8970200410
Rating:
Service parts 101402-4160 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
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
101402-4160
1014024160
ISUZU
8970200410
8970200410
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
3.6
3.55
3.65
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
10.6
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
159.2
157.6
160.8
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
106.6
106.6
Boost pressure
mmHg
800
800
Injection quantity adjustment_02
Adjusting point
B
Rack position
5.9+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
17.3
16
18.6
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
8.4
Boost pressure
kPa
20
17.3
22.7
Boost pressure
mmHg
150
130
170
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
(10.6)
Boost pressure
kPa
93.3
86.6
100
Boost pressure
mmHg
700
650
750
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)Boost compensator stroke
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=12deg+-5deg b=26deg+-5deg
----------
----------
a=12deg+-5deg b=26deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Speed = aa, rack position = bb (sealed at shipping)
----------
aa=0r/min bb=1-0.2mm
----------
a=32deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.2mm
----------
a=32deg+-5deg b=(55deg)
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=12deg
----------
a=(90deg)
----------
aa=12deg
----------
a=(90deg)
Information:
start by:a) remove timing gear cover1. Remove the turbocharger return tube from the flywheel housing. 2. Remove two studs (1).3. Turn the engine with tool (A) to remove four bolts (2) from the rear balance weight gear.4. Turn the engine again with tool (A) until the "V" marks on all the timing gears are in alignment with each other.5. With the timing marks in alignment, install tooling (B) in the location of rear studs (1). Make sure the bolts [tooling (B)] are in the rear balance weight gear. Tighten the bolts [tooling (B)] evenly until the rear balance weight gear is free of the camshaft. 6. Remove bolts (3) and thrust plate (4). Pull the camshaft forward as far as possible [approximately 1/4 in. (6.4 mm)]. 7. Remove four bolts (6) and plate (7).8. Remove bolts (5) and the thrust plates that hold balance gear (8) in position. The gear must be pulled forward as bolts (5) are removed.9. After bolts (5) are all removed, remove balance gear (8). If balance gear (8) can not be removed turn the engine a small amount with tool (A) until the gear is free.10. Remove the bearing from balance gear (8) with tooling (D) and an arbor press. 11. Remove crankshaft gear (9) with tool (C).Install Timing Gears
1. Install the bearing in the front balance gear with tooling (A) and an arbor press. The bearing joint must be on a center line of the balance gear with in 20°.2. Heat crankshaft gear (3) to a maximum temperature of 400°F (204°C). Install the gear with the notch in the gear in alignment with the pin in the crankshaft. 3. Install shaft (1) in balance gear (2). Install the bolts in the shaft. Put the complete unit in position behind the camshaft gear as shown. Make sure the "V" mark on the two gears are in alignment with each other. Tighten the bolts that hold the balance gear in position. 4. Install plate (5) and the four bolts that hold the balance gear to the shaft. Make sure the groove in the plate is toward the gear.5. Push the camshaft toward the rear of the engine. Install thrust plate (4) and the bolts that hold the camshaft in position. Make sure the "V" mark on the camshaft gear is in alignment with the "V" mark on the balance gear.6. Remove tooling (C) (the two bolts) from the rear balance weight gear. Turn the engine with tool (B) to install the four bolts that hold the rear balance weight gear to the camshaft.7. Install the two studs in the flywheel housing.8. Install the turbocharger return tube assembly.end by:a) install timing gear cover
1. Install the bearing in the front balance gear with tooling (A) and an arbor press. The bearing joint must be on a center line of the balance gear with in 20°.2. Heat crankshaft gear (3) to a maximum temperature of 400°F (204°C). Install the gear with the notch in the gear in alignment with the pin in the crankshaft. 3. Install shaft (1) in balance gear (2). Install the bolts in the shaft. Put the complete unit in position behind the camshaft gear as shown. Make sure the "V" mark on the two gears are in alignment with each other. Tighten the bolts that hold the balance gear in position. 4. Install plate (5) and the four bolts that hold the balance gear to the shaft. Make sure the groove in the plate is toward the gear.5. Push the camshaft toward the rear of the engine. Install thrust plate (4) and the bolts that hold the camshaft in position. Make sure the "V" mark on the camshaft gear is in alignment with the "V" mark on the balance gear.6. Remove tooling (C) (the two bolts) from the rear balance weight gear. Turn the engine with tool (B) to install the four bolts that hold the rear balance weight gear to the camshaft.7. Install the two studs in the flywheel housing.8. Install the turbocharger return tube assembly.end by:a) install timing gear cover