Information injection-pump assembly
ZEXEL
101431-0760
1014310760
ISUZU
5156011242
5156011242
Rating:
Service parts 101431-0760 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
11.8(120)
13.
NOZZLE-HOLDER
15.
NOZZLE SET
Cross reference number
ZEXEL
101431-0760
1014310760
ISUZU
5156011242
5156011242
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
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
2.25
2.2
2.3
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
11.5
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
40.8
39.8
41.8
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
12.2
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
39
37.6
40.4
Max. variation between cylinders
%
0
-4.5
4.5
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.6+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
8
6.9
9.1
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.
Timer adjustment
Pump speed
r/min
500+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
1
0.5
1.5
Timer adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
2
1.2
2.7
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
4.5
3.9
4.9
Timer adjustment_05
Pump speed
r/min
1750
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
P:Negative pressure
(1)Pneumatic governor
(2)Mechanical governor
(3)Acting negative pressure: P1
(4)Injection quantity Q = Q1 or less
----------
Q1=3mm3/st
----------
----------
Q1=3mm3/st
----------
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = at least aa
----------
aa=17.5mm
----------
a=2deg+-5deg b=(11deg) c=(22deg)
----------
aa=17.5mm
----------
a=2deg+-5deg b=(11deg) c=(22deg)
Timing setting
(1)Pump vertical direction
(2)Gear mark Z for the No. 4 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(60deg)
----------
aa=14deg
----------
a=(60deg)
Information:
2. Remove bolts (1) from the alternator bracket.3. Remove the bolts that hold plate (3), and remove the plate.4. Disconnect water line (2) from the air compressor. Turn the water line tee toward the lifting bracket in order to provide clearance to remove the head bolt. 5. Remove bolts (4) and (5) that hold the cylinder head assembly to the cylinder block.6. Fasten a hoist, and remove the cylinder head assembly. The weight is approximately 135 kg (300 lb.).
Do not put the cylinder head assembly down on a flat surface. This can cause damage to the fuel injection valves.
7. Remove the gasket, seals (6) and O-ring seal (7) from the spacer plate. The following steps are for installation of the cylinder head. Be sure a new gasket has been installed between the spacer plate and the cylinder block. See Remove And Install Spacer Plate.8. Thoroughly clean the spacer plate and the bottom surface of the cylinder head assembly. Install a new head gasket, new seals (6) and two O-ring seals (7).9. Fasten a hoist, and put the cylinder head assembly in position on the cylinder block. 10. Put clean engine oil on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in sequence shown.a. Tighten bolts 1 through 20 in number sequence to a torque of 270 25 N m (200 18 lb.ft.). b. Tighten bolts 1 through 20 in number sequence to a torque of 450 20 N m (330 15 lb.ft.).c. Tighten bolts 1 through 20 in number sequence to a torque of 450 20 N m (330 15 lb.ft.) by hand.d. Install the rocker shaft assemblies and push rods. See Install Rocker Shaft Assemblies And Push Rods.e. Tighten bolts 21 through 26 in number sequence to a torque of 270 25 N m (200 18 lb.ft.). f. Tighten bolts 21 through 26 in number sequence to a torque of 450 20 N m (330 15 lb.ft.). g. Tighten bolts 21 through 26 in number sequence to a torque of 450 20 N m (330 15 lb.ft.) by hand.h. Tighten the 3/8" bolts (5) to a torque of 43 7 N m (32 5 lb.ft.). If the studs for the exhaust manifold were removed, install new studs, and tighten them to a torque of 25 4 N m (18 3 lb.ft.)11. Make an adjustment to the valves to have a clearance of 0.38 mm (.015 in.) for intake and 0.76 mm (.030 in.) for exhaust. Tighten the locknuts for the valve adjustment screws to a torque of 28 4 N m (21 3 lb.ft.).12. Install the valve cover bases and the inner fuel lines. see Install Rocker Shaft Assemblies And Push Rods.13. Install the valve covers. See Install Valve Covers.14. Install pate (3).15. Connect water line (2) to the air compressor.16. Install bolts (1) for the alternator bracket.17. Install the
Do not put the cylinder head assembly down on a flat surface. This can cause damage to the fuel injection valves.
7. Remove the gasket, seals (6) and O-ring seal (7) from the spacer plate. The following steps are for installation of the cylinder head. Be sure a new gasket has been installed between the spacer plate and the cylinder block. See Remove And Install Spacer Plate.8. Thoroughly clean the spacer plate and the bottom surface of the cylinder head assembly. Install a new head gasket, new seals (6) and two O-ring seals (7).9. Fasten a hoist, and put the cylinder head assembly in position on the cylinder block. 10. Put clean engine oil on the threads of the cylinder head bolts. Install the cylinder head bolts and washers. Tighten the bolts in sequence shown.a. Tighten bolts 1 through 20 in number sequence to a torque of 270 25 N m (200 18 lb.ft.). b. Tighten bolts 1 through 20 in number sequence to a torque of 450 20 N m (330 15 lb.ft.).c. Tighten bolts 1 through 20 in number sequence to a torque of 450 20 N m (330 15 lb.ft.) by hand.d. Install the rocker shaft assemblies and push rods. See Install Rocker Shaft Assemblies And Push Rods.e. Tighten bolts 21 through 26 in number sequence to a torque of 270 25 N m (200 18 lb.ft.). f. Tighten bolts 21 through 26 in number sequence to a torque of 450 20 N m (330 15 lb.ft.). g. Tighten bolts 21 through 26 in number sequence to a torque of 450 20 N m (330 15 lb.ft.) by hand.h. Tighten the 3/8" bolts (5) to a torque of 43 7 N m (32 5 lb.ft.). If the studs for the exhaust manifold were removed, install new studs, and tighten them to a torque of 25 4 N m (18 3 lb.ft.)11. Make an adjustment to the valves to have a clearance of 0.38 mm (.015 in.) for intake and 0.76 mm (.030 in.) for exhaust. Tighten the locknuts for the valve adjustment screws to a torque of 28 4 N m (21 3 lb.ft.).12. Install the valve cover bases and the inner fuel lines. see Install Rocker Shaft Assemblies And Push Rods.13. Install the valve covers. See Install Valve Covers.14. Install pate (3).15. Connect water line (2) to the air compressor.16. Install bolts (1) for the alternator bracket.17. Install the