Information injection-pump assembly
ZEXEL
101402-4450
1014024450
ISUZU
8971379250
8971379250
Rating:
Service parts 101402-4450 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-331-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-4450
1014024450
ISUZU
8971379250
8971379250
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
8.6
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
87
85.9
88.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.1+-0.5
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
8.8
7.4
10.2
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)Tolerance for racks not indicated: +-0.05mm.
(3)Set idle sub-spring
(4)Main spring setting
----------
K=7
----------
----------
K=7
----------
Speed control lever angle
F:Full speed
I:Idle
D:Dead point
S:Stop
----------
----------
a=(2deg)+-5deg b=(16deg)+-5deg c=(17deg)+-5deg d-(13deg)+-3deg
----------
----------
a=(2deg)+-5deg b=(16deg)+-5deg c=(17deg)+-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=12deg
----------
a=(100deg)
----------
aa=12deg
----------
a=(100deg)
Information:
1. Remove shaft (2). Remove pin (1) from the shaft.2. Remove pins (3) from the flyweights. Remove flyweights (4). 3. Remove ring, races (6) and the bearing from riser (follower) (5). 4. Remove cover (7) and spring (8) from the governor housing. There is force on the cover from the spring.5. Remove seal (9) from the cover. 6. Remove cover (10) for the low and high idle adjustments.7. Remove locknut and screw (13) for the high idle adjustment.8. Remove bolt (15) and the washers for the low idle adjustment.9. Remove spring (16) and the guide.10. Remove pin (14) and plate (11).11. Remove shaft (12) from the housing. 12. Remove two spacers (17) and pin (18) from the shaft. 13. Remove shaft (19) from the governor housing.14. Remove washer (20) and levers (21) and (22) from the governor housing. 15. Remove seal (23) and the bearing.16. Remove seals (24) and (25) from the governor housing.Assemble Governor
1. Install the bearing and seal in the housing with tool (A). The lip of the seal must be toward the bearing. 2. Install seal (1) in housing with tool (A). The lip of the seal must be toward inside of housing.3. Install seal (2) in the housing with tool (B). The lip of the seal must be toward the inside of the housing. 4. Install shaft (3) in the housing. 5. Install plates (4), spacers (8) and pin (7) on shaft (5).6. Install shaft (5) in the housing and through washer (9) and levers (6). 7. Install pin (11) in the holes of the plates.8. Install screw (10) and the locknut for the high idle adjustment.9. Install spring (13) and the guide.10. Install bolt (12) and the washer for the low idle adjustment.11. Push plate and pin (11) over toward bolt (12) and tighten the bolt. 12. Install the seal in cover (14) with tooling (B). The lip of the seal must be toward the inside. 13. Install spring (15) in the cover. Install cover (14) on the housing.
Spring (15) must be installed with the end of the spring in the position shown.
14. Install the cover (16) for the idle adjustment screws. 15. Install bearing (19) between races (18) on riser (follower) (17). Install ring (20). Ring (20) holds the washers on the riser (follower).16. Install the pin in shaft (23). 17. Install flyweights (22) and pin (21).18. Install shaft (23) in the flyweight assembly.end by: a) connection of governor to fuel injection pump housingb) Make adjustment of fuel system setting (See Fuel System Setting in Testing and Adjusting.)
1. Install the bearing and seal in the housing with tool (A). The lip of the seal must be toward the bearing. 2. Install seal (1) in housing with tool (A). The lip of the seal must be toward inside of housing.3. Install seal (2) in the housing with tool (B). The lip of the seal must be toward the inside of the housing. 4. Install shaft (3) in the housing. 5. Install plates (4), spacers (8) and pin (7) on shaft (5).6. Install shaft (5) in the housing and through washer (9) and levers (6). 7. Install pin (11) in the holes of the plates.8. Install screw (10) and the locknut for the high idle adjustment.9. Install spring (13) and the guide.10. Install bolt (12) and the washer for the low idle adjustment.11. Push plate and pin (11) over toward bolt (12) and tighten the bolt. 12. Install the seal in cover (14) with tooling (B). The lip of the seal must be toward the inside. 13. Install spring (15) in the cover. Install cover (14) on the housing.
Spring (15) must be installed with the end of the spring in the position shown.
14. Install the cover (16) for the idle adjustment screws. 15. Install bearing (19) between races (18) on riser (follower) (17). Install ring (20). Ring (20) holds the washers on the riser (follower).16. Install the pin in shaft (23). 17. Install flyweights (22) and pin (21).18. Install shaft (23) in the flyweight assembly.end by: a) connection of governor to fuel injection pump housingb) Make adjustment of fuel system setting (See Fuel System Setting in Testing and Adjusting.)