Information injection-pump assembly
ZEXEL
101402-4161
1014024161
ISUZU
8970200411
8970200411
Rating:
Service parts 101402-4161 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97020-033-1
12.
Open Pre:MPa(Kqf/cm2)
22.1{225}
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-4161
1014024161
ISUZU
8970200411
8970200411
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
9.9
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
139
137.4
140.6
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.
15.5
14.2
16.8
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
8.3
Boost pressure
kPa
33.3
30.6
36
Boost pressure
mmHg
250
230
270
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
9
Boost pressure
kPa
53.3
49.3
57.3
Boost pressure
mmHg
400
370
430
Boost compensator adjustment_03
Pump speed
r/min
550
550
550
Rack position
(9.9)
Boost pressure
kPa
84
84
84
Boost pressure
mmHg
630
630
630
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Set idle sub-spring
(3)Main spring setting
(4)Boost compensator stroke
----------
K=20
----------
----------
K=20
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(21deg)+-5deg b=(26deg)+-5deg
----------
----------
a=(21deg)+-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 flywheelb) remove electric starting motorc) remove air compressord) remove turbochargere) remove oil pan 1. Remove the bolts from collar (2) and elbow (1).2. Remove the bolts from support (3). Remove bolts (4) from behind the support.3. Remove the exhaust manifold and support. Remove O-ring seal (5) from between the support and flywheel housing. 4. Fasten tooling (A) and a hoist to the flywheel housing (6). Remove the bolts that hold the flywheel housing in position. Remove the flywheel housing. Weight of the housing is 80 lb. (36 kg).
Do not cause damage to the crankshaft rear seal when the flywheel housing is removed.
Install Flywheel Housing
1. Install a new gasket on the rear of the engine block. 2. Put clean SAE 30 engine oil on the crankshaft rear seal wear sleeve and on the rear seal (2).3. Fasten a hoist and tooling (A) to flywheel housing (1). Put the flywheel housing in position on the engine block.
Be careful not to cause damage to the rear seal.
4. Install the bolts that hold the flywheel housing to the cylinder block. 5. Remove tooling (A). Install O-ring seal (5) on the oil (supply) hole in the flywheel housing and between the support.6. Put exhaust manifold and support (6) in position on the flywheel housing.7. Put 9M3710 Anti-Seize Compound on the bolts that hold the exhaust manifold and support. Install the bolts in the support.8. Install the gaskets between exhaust manifold collar (4) and at the elbow (3). Install the bolts and nuts that hold the manifolds together.end by: a) install oil panb) install turbochargerc) install air compressord) install electric startere) install flywheel
Do not cause damage to the crankshaft rear seal when the flywheel housing is removed.
Install Flywheel Housing
1. Install a new gasket on the rear of the engine block. 2. Put clean SAE 30 engine oil on the crankshaft rear seal wear sleeve and on the rear seal (2).3. Fasten a hoist and tooling (A) to flywheel housing (1). Put the flywheel housing in position on the engine block.
Be careful not to cause damage to the rear seal.
4. Install the bolts that hold the flywheel housing to the cylinder block. 5. Remove tooling (A). Install O-ring seal (5) on the oil (supply) hole in the flywheel housing and between the support.6. Put exhaust manifold and support (6) in position on the flywheel housing.7. Put 9M3710 Anti-Seize Compound on the bolts that hold the exhaust manifold and support. Install the bolts in the support.8. Install the gaskets between exhaust manifold collar (4) and at the elbow (3). Install the bolts and nuts that hold the manifolds together.end by: a) install oil panb) install turbochargerc) install air compressord) install electric startere) install flywheel