Information injection-pump assembly
ZEXEL
101402-7351
1014027351
ISUZU
8972050640
8972050640
Rating:
Service parts 101402-7351 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}
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-7351
1014027351
ISUZU
8972050640
8972050640
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
8.7
Pump speed
r/min
1025
1025
1025
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
6.2+-0.5
Pump speed
r/min
425
425
425
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=10
----------
----------
K=10
----------
Speed control lever angle
F:Full speed
I:Idle
D:Dead point
(1)With variable lever
----------
----------
a=(21deg)+-5deg b=(19deg)+-5deg c=(10deg)+-3deg
----------
----------
a=(21deg)+-5deg b=(19deg)+-5deg c=(10deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=6deg+-5deg b=46deg+-5deg
----------
----------
a=6deg+-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=12deg
----------
a=(100deg)
----------
aa=12deg
----------
a=(100deg)
Information:
Timing Gear Cover
Refer to SERVICE GUIDE for Preliminary Information.Two 3/8" NC Forcing Screws.
TIMING GEAR COVER1 Loosen bolt (2). Use two 3/8" NC forcing screws to remove pulley hub (1).2 At installation, tighten bolt to 230 20 lb. ft. (31,8 2,8 m.kg), tap bolt head with a hammer, and again tighten bolt to 230 20 lb. ft. (31,8 2,8 m. kg).3 Heat a new bushing in 250°F. (121°C.) oil for two hours before installation.4 Shim between trunnion hub and support halves to obtain a fit of .002 in. (0,05 mm) loose-to-.003 in. (0,07 mm) tight.5 Trim gasket flush with bottom face of cylinder block. Gaskets will leak if not cut square and flush with oil pan face.Timing Gears
Refer to SERVICE GUIDE for Preliminary Information.8S5132 Puller Plate,8S5133 Expansion Plug,8S6470 Pressure Screw,8B7561 Step Plate,Two 3/8" NF bolts.
Do not rotate the crankshaft with camshaft gear removed.
1 Use an 8S5132 Puller Plate, 8S5133 Expansion Plug, 8B7561 Step Plate, two 3/8" NF bolts and an 8S6470 Pressure Screw to remove gear. At installation, refer to topic FUEL INJECTION PUMP CAMSHAFT TIMING - FUEL SYSTEM - TESTING AND ADJUSTING.2 Fuel transfer pump must be removed before removing shaft. At installation, accessory drive shaft must be timed to crankshaft. Refer to FUEL INJECTION PUMP CAMSHAFT TIMING - FUEL SYSTEM - TESTING AND ADJUSTING.3 Trim gasket flush with bottom face of cylinder block. Gasket will leak if not cut square and flush with oil pan face.4, 6 Bearing must be centered in gear hub.5 Install washer with concave side toward gear (1).7 Align letter "C" on camshaft gear with letter "C" on crankshaft gear.8 Camshaft front bearing must be recessed .06 in. (1,52 mm) from front face of bore, oil hole in bearing must align with oil hole in cylinder block, and joint in bearing must face cylinder block centerline. Intermediate bearings must be flush with front face of bearing bore. Rear bearing must be recessed .06 in. (1,52 mm) from rear face of bore.Flywheel And Flywheel Housing
Refer to SERVICE GUIDE for Preliminary Information.FT125 Pilot and FT638 Sleeve (Fabricated Tools),5H1504 Washer,2J3506 Nut. 1, 2 Align mark on flywheel with mark on crankshaft.3 Heat ring gear. Do not exceed 600°F. (315°C.). Install with chamfered portion of ring gear teeth toward starter pinion when flywheel is installed.4 Use FT125 Pilot, FT638 Sleeve, 5H1504 Washer and a 2J3506 Nut to install seal.5 Trim gasket flush with bottom face of cylinder block. Gasket will leak if not cut square and flush with oil pan face.
This is an example of installing the crankshaft rear seal. A-FT638 Sleeve. B-2J3506 Nut. C-5H1504 Washer. D-FT125 Pilot. Secure pilot to crankshaft with three 5/8"-18 NF bolts, 2 in. (50,8 mm) long. Grind bolt head as necessary to provide seal clearance.
Refer to SERVICE GUIDE for Preliminary Information.Two 3/8" NC Forcing Screws.
TIMING GEAR COVER1 Loosen bolt (2). Use two 3/8" NC forcing screws to remove pulley hub (1).2 At installation, tighten bolt to 230 20 lb. ft. (31,8 2,8 m.kg), tap bolt head with a hammer, and again tighten bolt to 230 20 lb. ft. (31,8 2,8 m. kg).3 Heat a new bushing in 250°F. (121°C.) oil for two hours before installation.4 Shim between trunnion hub and support halves to obtain a fit of .002 in. (0,05 mm) loose-to-.003 in. (0,07 mm) tight.5 Trim gasket flush with bottom face of cylinder block. Gaskets will leak if not cut square and flush with oil pan face.Timing Gears
Refer to SERVICE GUIDE for Preliminary Information.8S5132 Puller Plate,8S5133 Expansion Plug,8S6470 Pressure Screw,8B7561 Step Plate,Two 3/8" NF bolts.
Do not rotate the crankshaft with camshaft gear removed.
1 Use an 8S5132 Puller Plate, 8S5133 Expansion Plug, 8B7561 Step Plate, two 3/8" NF bolts and an 8S6470 Pressure Screw to remove gear. At installation, refer to topic FUEL INJECTION PUMP CAMSHAFT TIMING - FUEL SYSTEM - TESTING AND ADJUSTING.2 Fuel transfer pump must be removed before removing shaft. At installation, accessory drive shaft must be timed to crankshaft. Refer to FUEL INJECTION PUMP CAMSHAFT TIMING - FUEL SYSTEM - TESTING AND ADJUSTING.3 Trim gasket flush with bottom face of cylinder block. Gasket will leak if not cut square and flush with oil pan face.4, 6 Bearing must be centered in gear hub.5 Install washer with concave side toward gear (1).7 Align letter "C" on camshaft gear with letter "C" on crankshaft gear.8 Camshaft front bearing must be recessed .06 in. (1,52 mm) from front face of bore, oil hole in bearing must align with oil hole in cylinder block, and joint in bearing must face cylinder block centerline. Intermediate bearings must be flush with front face of bearing bore. Rear bearing must be recessed .06 in. (1,52 mm) from rear face of bore.Flywheel And Flywheel Housing
Refer to SERVICE GUIDE for Preliminary Information.FT125 Pilot and FT638 Sleeve (Fabricated Tools),5H1504 Washer,2J3506 Nut. 1, 2 Align mark on flywheel with mark on crankshaft.3 Heat ring gear. Do not exceed 600°F. (315°C.). Install with chamfered portion of ring gear teeth toward starter pinion when flywheel is installed.4 Use FT125 Pilot, FT638 Sleeve, 5H1504 Washer and a 2J3506 Nut to install seal.5 Trim gasket flush with bottom face of cylinder block. Gasket will leak if not cut square and flush with oil pan face.
This is an example of installing the crankshaft rear seal. A-FT638 Sleeve. B-2J3506 Nut. C-5H1504 Washer. D-FT125 Pilot. Secure pilot to crankshaft with three 5/8"-18 NF bolts, 2 in. (50,8 mm) long. Grind bolt head as necessary to provide seal clearance.