Information injection-pump assembly
ZEXEL
101402-7102
1014027102
ISUZU
8971660781
8971660781
Rating:
Service parts 101402-7102 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
101402-7102
as INJECTION-PUMP ASSEMBLY
Include in #2:
104056-0251
as _
Cross reference number
ZEXEL
101402-7102
1014027102
ISUZU
8971660781
8971660781
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
3.2
3.15
3.25
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
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
90.5
89.4
91.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
8
6.6
9.4
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
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
(1)Stopper bolt setting
----------
----------
a=25deg+-5deg b=6deg+-5deg
----------
----------
a=25deg+-5deg b=6deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=4.5deg+-5deg b=53deg+-5deg
----------
----------
a=4.5deg+-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=14deg
----------
a=(100deg)
----------
aa=14deg
----------
a=(100deg)
Information:
start by:a) remove fuel shutoff solenoidb) remove fuel ratio control1. Make a setting of the fuel injection pump timing as follows: a) Turn the engine clockwise (as seen from the front of the engine) with tool (B) to top center of the compression stroke of No. 1 piston. See FINDING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING. b) Remove the plug from the side of fuel injection pump housing. Install tool (A) through the hole in pump housing and into the notch in the injection pump camshaft. If tool (A) can not be installed in the notch of the injection pump camshaft, the injection pump is not in time with the engine and the following procedure must be followed: a) Remove nuts (1). Remove cover (2) for the automatic timing advance.b) Loosen bolt (3) and hit the bolt with a soft hammer to loosen the automatic timing advance. c) Remove bolt (3) and washer (4). Install the bolt again.d) Turn the fuel injection pump drive shaft clockwise with bolt (3) until tool (A) can be put into the notch in the injection pump camshaft.e) Remove the bolt. Install washer (4) and bolt (3) so the washer is loose.
TYPICAL EXAMPLEf) Remove the timing bolt from the flywheel. Turn the engine 60° counterclockwise (as seen from the front of the engine) with tool (B).g) Tighten the bolt that holds the automatic timing advance by hand. Turn the engine clockwise (as seen from the front of the engine) with tool (B) until the engine is at top center compression stroke of No. 1 piston.h) Tighten bolt (3) to a torque of 15 lb.ft. (20 N m). Remove tool (A) from the fuel injection pump housing. Tighten bolt (3) to a torque of 110 10 lb.ft. (149 14 N m).
Do not tighten the bolt to final torque until tool (A) is removed.
i) Turn the crankshaft counterclockwise (as seen from the front of the engine) two complete revolutions and check the timing to see that timing is correct.j) If timing is not correct, do the above procedure again.k) Install the cover for the automatic timing advance and the nuts that hold it. 2. Disconnect fuel lines (5) and (7) from the fuel injection pump housing.3. Disconnect fuel injection lines (9) from the fuel injection pump housing. Install caps and plugs in all fuel line openings.4. Remove two bolts (8) that hold bracket (6) to the governor housing. 5. Fasten a nylon strap and a hoist to the fuel injection pump housing. Remove bolts (12) and (10) that hold the fuel injection pump housing to the cylinder block.6. Remove bolts (11) that hold the fuel injection pump housing to the fuel injection pump and governor drive housing.7. Remove fuel injection pump housing and governor. The weight is 70 lb. (32 kg).Remove Fuel Injection Pump Housing And Governor (Later)
start by:a) remove fuel shutoff solenoidb) remove fuel ratio control1. Make a setting of the fuel injection pump timing as
TYPICAL EXAMPLEf) Remove the timing bolt from the flywheel. Turn the engine 60° counterclockwise (as seen from the front of the engine) with tool (B).g) Tighten the bolt that holds the automatic timing advance by hand. Turn the engine clockwise (as seen from the front of the engine) with tool (B) until the engine is at top center compression stroke of No. 1 piston.h) Tighten bolt (3) to a torque of 15 lb.ft. (20 N m). Remove tool (A) from the fuel injection pump housing. Tighten bolt (3) to a torque of 110 10 lb.ft. (149 14 N m).
Do not tighten the bolt to final torque until tool (A) is removed.
i) Turn the crankshaft counterclockwise (as seen from the front of the engine) two complete revolutions and check the timing to see that timing is correct.j) If timing is not correct, do the above procedure again.k) Install the cover for the automatic timing advance and the nuts that hold it. 2. Disconnect fuel lines (5) and (7) from the fuel injection pump housing.3. Disconnect fuel injection lines (9) from the fuel injection pump housing. Install caps and plugs in all fuel line openings.4. Remove two bolts (8) that hold bracket (6) to the governor housing. 5. Fasten a nylon strap and a hoist to the fuel injection pump housing. Remove bolts (12) and (10) that hold the fuel injection pump housing to the cylinder block.6. Remove bolts (11) that hold the fuel injection pump housing to the fuel injection pump and governor drive housing.7. Remove fuel injection pump housing and governor. The weight is 70 lb. (32 kg).Remove Fuel Injection Pump Housing And Governor (Later)
start by:a) remove fuel shutoff solenoidb) remove fuel ratio control1. Make a setting of the fuel injection pump timing as