Information injection-pump assembly
ZEXEL
101491-0213
1014910213
ISUZU
8941279562
8941279562
Rating:
Service parts 101491-0213 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94151-865-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101491-0213
1014910213
ISUZU
8941279562
8941279562
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)
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
Rack position
Point A R=A
Point A R=A
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
-
Rack position
10.5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
59.2
57.6
60.8
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.8+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
9.5
8
11
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.5)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
59.2
58.2
60.2
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.05
Pump speed
r/min
1800
1800
1800
Average injection quantity
mm3/st.
61.3
58.1
64.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
43.5
40.3
46.7
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
46.1
42.1
50.1
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
66
50
82
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1650--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1600
Advance angle
deg.
0.6
Timer adjustment_03
Pump speed
r/min
1800
Advance angle
deg.
3
2.5
3.5
Timer adjustment_04
Pump speed
r/min
1900
Advance angle
deg.
4.5
4
5
Timer adjustment_05
Pump speed
r/min
-
Advance angle
deg.
5
5
5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)The torque cam setting and high idle must be set when speed is increasing from low to high (because of hysterisis).
----------
T1=A73
----------
----------
T1=A73
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
(2)Speed = aa, rack position = bb (lever angle with microswitch ON)
----------
aa=1285+-50r/min bb=9.2mm
----------
a=5.5deg+-5deg b=(41deg)+-3deg c=(20deg)+-3deg
----------
aa=1285+-50r/min bb=9.2mm
----------
a=5.5deg+-5deg b=(41deg)+-3deg c=(20deg)+-3deg
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:
Removal of Lubrication System (1)
Removal of Lubrication System (2)
Disassembly Inspection and Reassembly Of Lubrication System
Oil Pump
Disassembly and Inspection of Oil Pump
Measurement of Clearance between Outer Rotor and Inner Rotor
Measure the clearance between the outer rotor and inner rotor, and, if the limit value is exceeded, replace the pump assembly.
Measurement of clearance between outer rotor and inner rotor Measurement of Rotor and Case End Play
Measure the rotor and case end play, and, if the limit value is exceeded, replace the pump assembly.
Measurement of rotor and case end play Measurement of Clearance Between Outer Rotor and Pump Case
Measure the clearance between the outer rotor and pump case, and, if the limit value is exceeded, replace the pump assembly.
Measure the clearance between the outer rotor and case Reassembly of Oil Pump
Install the outer rotor to the pump case, check alignment mark (indentation) on the pump case cover, and then tighten the bolts. If the alignment marks are not aligned during the reassembly, the pump will not suck oil.
Alignment marks on pump case and pump case coverOil Filter and Oil Cooler
Disassembly and Inspection of Oil Filter and Oil Cooler
Relief Valve
Inspection of Relief Valve
Relief Valve(1) Check the relief valve and valve seat for contact condition, and the spring for fatigue and damage, and replace any defective parts.(2) Measure the valve opening pressure (oil pressure when the engine is running at rated rpm) of the relief valve, and, if the standard valve is exceeded, remove the cap bolt and make an adjustment by increasing or decreasing the shim thickness.Engine oil pressure take-out port Next to oil filter - Rp 1/8 thread (PS 1/8) Installation of Lubrication System (1)
Installation of Lubrication System (2)
Removal of Lubrication System (2)
Disassembly Inspection and Reassembly Of Lubrication System
Oil Pump
Disassembly and Inspection of Oil Pump
Measurement of Clearance between Outer Rotor and Inner Rotor
Measure the clearance between the outer rotor and inner rotor, and, if the limit value is exceeded, replace the pump assembly.
Measurement of clearance between outer rotor and inner rotor Measurement of Rotor and Case End Play
Measure the rotor and case end play, and, if the limit value is exceeded, replace the pump assembly.
Measurement of rotor and case end play Measurement of Clearance Between Outer Rotor and Pump Case
Measure the clearance between the outer rotor and pump case, and, if the limit value is exceeded, replace the pump assembly.
Measure the clearance between the outer rotor and case Reassembly of Oil Pump
Install the outer rotor to the pump case, check alignment mark (indentation) on the pump case cover, and then tighten the bolts. If the alignment marks are not aligned during the reassembly, the pump will not suck oil.
Alignment marks on pump case and pump case coverOil Filter and Oil Cooler
Disassembly and Inspection of Oil Filter and Oil Cooler
Relief Valve
Inspection of Relief Valve
Relief Valve(1) Check the relief valve and valve seat for contact condition, and the spring for fatigue and damage, and replace any defective parts.(2) Measure the valve opening pressure (oil pressure when the engine is running at rated rpm) of the relief valve, and, if the standard valve is exceeded, remove the cap bolt and make an adjustment by increasing or decreasing the shim thickness.Engine oil pressure take-out port Next to oil filter - Rp 1/8 thread (PS 1/8) Installation of Lubrication System (1)
Installation of Lubrication System (2)