Information injection-pump assembly
ZEXEL
101402-7340
1014027340
ISUZU
8972034760
8972034760
Rating:
Service parts 101402-7340 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
101402-7340
1014027340
ISUZU
8972034760
8972034760
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
9.2
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
85
83.9
86.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.3+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
9
7.6
10.4
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
100
100
110
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
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=7deg+-5deg b=23deg+-5deg
----------
----------
a=7deg+-5deg b=23deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=46deg+-5deg
----------
----------
a=12deg+-5deg b=46deg+-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=15deg
----------
a=(100deg)
----------
aa=15deg
----------
a=(100deg)
Information:
Pressing Parts
When one part is pressed into another, use white lead or a suitable prepared compound to lubricate the mating surfaces.Assemble tapered parts dry. Before assembling parts with tapered splines, be sure the splines are clean, dry and free from burrs. Position the parts together by hand to mesh the splines before applying pressure.Parts which are fitted together with tapered splines are always very tight. If they are not tight, inspect the tapered splines and discard the part if the splines are worn.Bolts And Bolt Torque
Use bolts of the correct length. A bolt which is too long may "bottom" before the head is tight against the part it is to hold. The threads can be damaged when a "long" bolt is removed.If a bolt is too short, there may not be enough threads engaged to hold the part securely.Apply proper torque values to all bolts and nuts when assembling Caterpillar equipment. When a specific torque value is required, the value is listed in the SPECIFICATIONS or the DISASSEMBLY AND ASSEMBLY sections of the Service Manual. Tighten all other bolts and nuts for general usage, hydraulic valve bodies, or taperlock studs to the torque values given in the charts at the front of the SPECIFICATIONS.Locks
Lockwashers, flat metal locks or cotter pins are used to lock nuts and bolts.Flat metal locks must be installed properly to be effective. Bend one end of the lock around the edge of the part. Bend the other end against one flat surface of the nut or bolt head.Always install new locks in compartments which house moving parts.When installing lockwashers on housings made of aluminum, use a flat washer between the lockwasher and the housing.
Correct and incorrect methods of installing flat metal locks.
Correct and incorrect method for lock positioning and bending.Lines And Wires
When removing or disconnecting a group of lines or wires, tag each one to assure proper assembly.Lubrication
Where applicable, fill the compartments of the components serviced with the amount, type and grade of lubricant recommended in the Lubrication and Maintenance Information part of this Manual.Rust Preventive Compound
Clean the rust preventive compound from all machined surfaces of new parts before installing them.Shims
When shims are removed, tie them together and identify them as to location. Keep shims clean and flat until they are reinstalled.Bearings
Anti-Friction Bearings
When an anti-friction bearing is removed, cover it to keep out dirt and abrasives. Wash bearings in nonflammable cleaning solution and allow them to drain dry. The bearing may be dried with compressed air but do not spin the bearing.Discard the bearings if the races and balls or rollers are pitted, scored or burned. If the bearing is serviceable, coat it with oil and wrap it in clean paper. Do not unwrap new bearings until time of installation.The life of an anti-friction bearing will be shortened if not properly lubricated. Dirt in an anti-friction bearing can cause the bearing to lock resulting in the shaft turning in the inner race or the outer race turning within the cage.
Effect of dirt in bearing.Double
When one part is pressed into another, use white lead or a suitable prepared compound to lubricate the mating surfaces.Assemble tapered parts dry. Before assembling parts with tapered splines, be sure the splines are clean, dry and free from burrs. Position the parts together by hand to mesh the splines before applying pressure.Parts which are fitted together with tapered splines are always very tight. If they are not tight, inspect the tapered splines and discard the part if the splines are worn.Bolts And Bolt Torque
Use bolts of the correct length. A bolt which is too long may "bottom" before the head is tight against the part it is to hold. The threads can be damaged when a "long" bolt is removed.If a bolt is too short, there may not be enough threads engaged to hold the part securely.Apply proper torque values to all bolts and nuts when assembling Caterpillar equipment. When a specific torque value is required, the value is listed in the SPECIFICATIONS or the DISASSEMBLY AND ASSEMBLY sections of the Service Manual. Tighten all other bolts and nuts for general usage, hydraulic valve bodies, or taperlock studs to the torque values given in the charts at the front of the SPECIFICATIONS.Locks
Lockwashers, flat metal locks or cotter pins are used to lock nuts and bolts.Flat metal locks must be installed properly to be effective. Bend one end of the lock around the edge of the part. Bend the other end against one flat surface of the nut or bolt head.Always install new locks in compartments which house moving parts.When installing lockwashers on housings made of aluminum, use a flat washer between the lockwasher and the housing.
Correct and incorrect methods of installing flat metal locks.
Correct and incorrect method for lock positioning and bending.Lines And Wires
When removing or disconnecting a group of lines or wires, tag each one to assure proper assembly.Lubrication
Where applicable, fill the compartments of the components serviced with the amount, type and grade of lubricant recommended in the Lubrication and Maintenance Information part of this Manual.Rust Preventive Compound
Clean the rust preventive compound from all machined surfaces of new parts before installing them.Shims
When shims are removed, tie them together and identify them as to location. Keep shims clean and flat until they are reinstalled.Bearings
Anti-Friction Bearings
When an anti-friction bearing is removed, cover it to keep out dirt and abrasives. Wash bearings in nonflammable cleaning solution and allow them to drain dry. The bearing may be dried with compressed air but do not spin the bearing.Discard the bearings if the races and balls or rollers are pitted, scored or burned. If the bearing is serviceable, coat it with oil and wrap it in clean paper. Do not unwrap new bearings until time of installation.The life of an anti-friction bearing will be shortened if not properly lubricated. Dirt in an anti-friction bearing can cause the bearing to lock resulting in the shaft turning in the inner race or the outer race turning within the cage.
Effect of dirt in bearing.Double