Information injection-pump assembly
ZEXEL
101402-4210
1014024210
ISUZU
8970486830
8970486830
Rating:
Service parts 101402-4210 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97030-285-1
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-4210
1014024210
ISUZU
8970486830
8970486830
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
9.6
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
59.1
58
60.2
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.5+-0.5
Pump speed
r/min
440
440
440
Average injection quantity
mm3/st.
10
8.6
11.4
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
----------
K=8
----------
----------
K=8
----------
Speed control lever angle
F:Full speed
I:Idle
D:Dead point
S:Stop
----------
----------
a=(18deg)+-5deg b=(14deg)+-5deg c=(18deg)+-5deg d=13deg+-3deg
----------
----------
a=(18deg)+-5deg b=(14deg)+-5deg c=(18deg)+-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.
----------
----------
----------
----------
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=16deg
----------
a=(90deg)
----------
aa=16deg
----------
a=(90deg)
Information:
1. Remove five bolts (1) that hold oil lines bracket and supports to the engine.2. Remove three bolts (2) that hold oil pump to the engine.3. Remove the oil pump with the lines as a unit from under the engine. 4. Remove oil lines (3) from the oil pump.Install Oil Pump (Brakesaver)
1. Put clean SAE 30 engine oil on the O-ring seals. Connect the oil lines in the oil pump. Install the bolt and washer that holds the line in the pump.2. Put the oil pump and the oil lines as a unit in position under the engine.3. Install the three bolts that hold the pump to the engine. Make sure the oil pump gear is engaged with crankshaft gear.4. Install the five bolts that hold the oil lines bracket and support to the engine.end by:a) install oil panDisassemble Oil Pump (Brakesaver)
start by:a) remove oil pump1. Remove bolt and washer that hold gear on the shaft. 2. Use tooling (A) to remove drive gear (1) from shaft. Remove the key from shaft. Put marks on the pump bodies so they can be assembled in the correct position.3. Remove retainer (3) for bypass valve. Remove spring and bypass valve. 4. Remove bolts (4) that hold pump body (2) to the main pump body. Remove the pump body (2).5. Use tooling (B) to remove the bearings from pump body (2). 6. Remove the gears (7). Put marks on the gears so they can be assembled in the same position.7. Remove the spacer (6) from the main oil pump body (5). Use tooling (C) to remove the bearings from spacer (6).8. Remove the gears from main pump body (5). 9. Use tooling (C) to remove the bearings from the main pump body.Assemble Oil Pump (Brakesaver)
1. Use tooling (A) to install the bearings (2) until they are even with the outside surface of the main pump body (1). Install the bearings (2) so the junctions in the bearings are 30° 15° from the center of the bearing bores and toward the oil pump outlet passage as shown. 2. Use tooling (A) to install the bearings (3) in the spacer. Install the bearings until they are in position an equal distance in from each side of the spacer. Install the bearings with the oil holes in the bearings in alignment with the oil holes in the spacer and the junctions in the bearings in alignment with the cavity in the spacer as shown. 3. Put clean engine oil on all gears and bearings before they are assembled in the oil pump. Install the idler and drive gears (5) in the main pump body.4. Install the spacer (4) on the gear shafts with the smaller cavity out and the oil holes in the spacer toward the pump outlet passage as shown. 5. Use tooling (B) to install the bearings (6) in the pump body (7) until they are .060 .010 in. (1.52 0.25 mm) from the inside edge of the bearing
1. Put clean SAE 30 engine oil on the O-ring seals. Connect the oil lines in the oil pump. Install the bolt and washer that holds the line in the pump.2. Put the oil pump and the oil lines as a unit in position under the engine.3. Install the three bolts that hold the pump to the engine. Make sure the oil pump gear is engaged with crankshaft gear.4. Install the five bolts that hold the oil lines bracket and support to the engine.end by:a) install oil panDisassemble Oil Pump (Brakesaver)
start by:a) remove oil pump1. Remove bolt and washer that hold gear on the shaft. 2. Use tooling (A) to remove drive gear (1) from shaft. Remove the key from shaft. Put marks on the pump bodies so they can be assembled in the correct position.3. Remove retainer (3) for bypass valve. Remove spring and bypass valve. 4. Remove bolts (4) that hold pump body (2) to the main pump body. Remove the pump body (2).5. Use tooling (B) to remove the bearings from pump body (2). 6. Remove the gears (7). Put marks on the gears so they can be assembled in the same position.7. Remove the spacer (6) from the main oil pump body (5). Use tooling (C) to remove the bearings from spacer (6).8. Remove the gears from main pump body (5). 9. Use tooling (C) to remove the bearings from the main pump body.Assemble Oil Pump (Brakesaver)
1. Use tooling (A) to install the bearings (2) until they are even with the outside surface of the main pump body (1). Install the bearings (2) so the junctions in the bearings are 30° 15° from the center of the bearing bores and toward the oil pump outlet passage as shown. 2. Use tooling (A) to install the bearings (3) in the spacer. Install the bearings until they are in position an equal distance in from each side of the spacer. Install the bearings with the oil holes in the bearings in alignment with the oil holes in the spacer and the junctions in the bearings in alignment with the cavity in the spacer as shown. 3. Put clean engine oil on all gears and bearings before they are assembled in the oil pump. Install the idler and drive gears (5) in the main pump body.4. Install the spacer (4) on the gear shafts with the smaller cavity out and the oil holes in the spacer toward the pump outlet passage as shown. 5. Use tooling (B) to install the bearings (6) in the pump body (7) until they are .060 .010 in. (1.52 0.25 mm) from the inside edge of the bearing