Information injection-pump assembly
ZEXEL
101402-4230
1014024230
ISUZU
8970703440
8970703440
Rating:
Service parts 101402-4230 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
101402-4230
1014024230
ISUZU
8970703440
8970703440
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
134424-1920
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
B
Rack position
9.5
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
64.6
63.1
66.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.7+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
10.4
9
11.8
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=7
----------
----------
K=7
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa
(2)Stopper bolt setting
(3)Set the pump speed at bb.
(4)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=19deg+-5deg b=1deg+-5deg c=5deg+-5deg
----------
aa=900r/min bb=750r/min
----------
a=19deg+-5deg b=1deg+-5deg c=5deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=66.5deg+-5deg b=53deg+-5deg
----------
----------
a=66.5deg+-5deg b=53deg+-5deg
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 pistons 1. Remove bearings (3) from the connecting rod and connecting rod cap.2. Remove retainer ring (1) with tool (A).3. Remove pin (2) and connecting rod (4) from the piston. 4. Remove the piston rings (5) from the piston with tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See USE OF PISTON PIN BEARING REMOVAL AND INSTALLATION TOOLS, SPECIAL INSTRUCTIONS, Form No. SMHS7295.5. Heat the connecting rod (4) in an oven to a temperature of 350°-500°F (177°-260°C). Never use a direct flame to heat a connecting rod. 6. Put connecting rod (4) in position on the base plate of tooling (C). Put a new rod pin bearing (6) on the adapter part of tooling (C). The old bearing is pushed out by tooling (C) as the new bearing is installed.7. Use tooling (C) to push the new bearing into the connecting rod until the push adapter of tooling (C) makes full contact with the connecting rod surface.8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 2.0012 .0003 in. (50.830 0.008 mm).9. Check the clearance between the ends of the piston rings. See PISTONS AND RINGS in SPECIFICATIONS.10. Install the oil ring spring in the oil ring groove of the piston. The oil ring is to be installed over the spring with the oil ring end gap 180° from the oil ring spring joint. 11. Install the oil ring on the piston with tool (B).12. Install the second (intermediate) piston ring with the side that has the identification "UP-2" toward the top of the piston with tool (B).13. Install the first (top) piston ring with the side that has the identification "UP-1" toward the top of the piston with tool (B). After the installation of all three piston rings, put the piston rings in position so the end gaps are 120° apart. 14. Put the piston in position on connecting rod (4). Put clean engine oil on pin (2) and install the pin. Install retainer rings (1) with tool (A). Make sure the retainer rings are in the grooves of the piston.15. Install bearings (3) in the connecting rod and connecting rod cap.end by:a) install pistons