Information injection-pump assembly
ZEXEL
101402-4251
1014024251
ISUZU
8970781570
8970781570
Rating:
Service parts 101402-4251 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-103-2
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-4251
1014024251
ISUZU
8970781570
8970781570
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
7.9
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
62
60.9
63.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
5.9+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
9
7.6
10.4
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.
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
86
86
96
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Rack difference between N = N1 and N = N2
----------
K=13 N1=1250r/min N2=700r/min
----------
----------
K=13 N1=1250r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=13deg+-5deg b=25deg+-5deg c=35deg+-3deg
----------
----------
a=13deg+-5deg b=25deg+-5deg c=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=19deg+-5deg b=53deg+-5deg
----------
----------
a=19deg+-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:
Firing order (injection sequence) ... 1, 5, 3, 6, 2, 4Injection timing before TC (top center) ... 12° 1°Injection timing before TC (top center) [aftercooled] ... 8° 30' 1°Torque for bolt in hole for timing pin ... 108 36 lb. in.(12.2 4.1 N m)Torque for bolts that hold governor weight carrier to camshaft ... 90 10 lb. in.(10.2 1.1 N m)(1) Diameter of rear bearing surface (journal) of the camshaft (new) ... 2.3720 .0005 in.(60.249 0.013 mm) Bore in the rear bearing for the camshaft (new) ... 2.3750 .0005 in.(60.325 0.013 mm)Maximum permissible clearance between the bearing and the camshaft bearing surface (journal) (worn) ... .006 in.(0.15 mm)(2) Diameter of sleeve control shaft (new) ... .3530 .0003 in.(8.966 0.008 mm) Bore in the housing for the fuel control shaft (new) ... .3543 .0005 in.(8.999 0.013 mm)Maximum permissible clearance between the bore in the housing and the sleeve control shaft (worn) ... .003 in.(0.08 mm)(3) End play for camshaft with sleeve installed (new) ... .023 .018 in.(0.58 0.46 mm) When installing sleeve on end of camshaft, support the camshaft to prevent damage to parts inside of injection pump and governor housing.(4) Diameter of front bearing surface (journal) of the camshaft (new) ... .9990 .0005 in.(25.375 0.013 mm) Bore in the front bearing for the camshaft (new) ... 1.0005 .0005 in.(25.413 0.013 mm)Maximum permissible clearance between the bearing and the camshaft bearing surface (journal) (worn) ... .003 in.(0.08 mm) Install spring washer with bent side towards the governor spring (5) as shown.(5) Governor Spring: (6) Bypass valve: If the spring keeps the pressure in the fuel injection pump housing above 25 psi (170 kPa) with the engine operating under full load, the spring is good.Pressure of fuel in housing for fuel injection pumps, (Full Load) ... 30 5 psi(205 35 kPa) Install guide pin (A) to depth (B) [.642 .003 in. (16.31 0.08 mm)]. Slot in guide pin (A) must be in area shown from center of lifter. (7) Torque for bushing ... 70 5 lb. ft.(95 7 N m)(8) 4N4318 Spring for injection pump: Length under test force ... 1.35 in.(34.3 mm)Test force ... 12.5 1.3 lb.(56 6 N)Free length after test ... 1.566 in.(39.78 mm)Outside diameter ... .728 in.(18.49 mm)(9) Torque for bolt holding sleeve on control shaft ... 24 2 lb. in.(2.8 0.2 N m) (10) Torque for the nuts that hold the fuel lines (Use 5P144 Fuel line Socket) ... 30 5 lb. ft.(40 7 N m)(11) Torque for the nuts that hold the nozzles ... 105 5 lb. ft.(142 7 N m)(12) Body.(13) Put 5P3931 Anti-Seize Compound on threads of glow plug and tighten to ... 120 24 lb. in.(13.6 2.8 N m)(14) Tighten nozzle finger tight on body.(15) Torque for precombustion chamber (put 5P3931 Anti-Seize Compound on threads)