Information injection-pump assembly
ZEXEL
101491-0530
1014910530
ISUZU
8970251390
8970251390
Rating:
Cross reference number
ZEXEL
101491-0530
1014910530
ISUZU
8970251390
8970251390
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
3.8
3.75
3.85
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. 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
12.3
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
56.5
54.9
58.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
10
8.7
11.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.3)
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
56.5
55.5
57.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.35
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
75.8
71.8
79.8
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
86
70
102
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1525--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1475
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1775
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)At delivery (at R = A, N = N1)
----------
T1=E97 N1=100r/min
----------
----------
T1=E97 N1=100r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
(2)Set the idle side stopper bolt at speed = aa and rack position = bb (at delivery)
----------
aa=100r/min bb=R1(12.3)mm
----------
a=(8deg) b=37.5deg+-3deg c=2.5deg+-5deg
----------
aa=100r/min bb=R1(12.3)mm
----------
a=(8deg) b=37.5deg+-3deg c=2.5deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=45deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
a=45deg+-5deg b=29deg+-5deg
0000001501 I/P WITH LOAD PLUNGER ADJ
Plunger assembly number: PL (stamping: ST)
1. Adjustment procedures
(1)Insert the pre-stroke adjusting shims L1 for each cylinder.
(2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2)
(3)At basic point A, adjust so that the pre-stroke is L2.
(4)Reconfirm the injection quantity.
----------
PL=131154-1820 ST=A260 L1=1mm L2=3.8+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131154-1820 ST=A260 L1=1mm L2=3.8+-0.05mm a1=+-14% a2=+-2.5%
----------
0000001601 FICD
1. FICD adjustment
(1)FICD adjustment not necessary.
(2)Set the clearance between the actuator rod and speed lever to approx. L1.
----------
L1=3+1mm
----------
----------
L1=3+1mm
----------
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=(90deg)
----------
aa=15deg
----------
a=(90deg)
Information:
start by:a) remove fuel injection lines**This operation location is in the ENGINE DISASSEMBLY AND ASSEMBLY section. 1. Disconnect the fuel lines from fuel transfer pump (4) and fuel manifold (3). Disconnect fuel line (2) from the fitting. Disconnect the fuel return line to the tank at (1). Install plugs or caps on all fuel line openings.2. Disconnect drain line (5) from the governor housing. Move the fuel lines and drain line clear of the fuel injection pump housing and governor. 3. Remove bolts (6) that hold the oil manifold to the governor housing. 4. Remove cover (7) from the timing gear cover.5. Remove the bolt and washer that hold the timing gear to the camshaft in the fuel injection pump housing. 6. Install tooling (A) and loosen the timing gear on the camshaft in the fuel injection pump housing.7. Fasten a strap and hoist to the fuel injection pump housing and governor as shown. 8. Remove three nuts (8) and remove the fuel injection pump housing and governor. Weight is 25 kg (56 lb.).Install Fuel Injection Pump Housing And Governor
1. Be sure O-ring seals (1) and (2) are in position on the fuel injection pump housing and governor and put clean oil on the O-ring seals.2. Remove the cover on the fuel injection pump housing and install timing pin (A). Turn the camshaft until timing pin (A) goes in the groove in the camshaft as shown. 3. Fasten a strap and hoist to the fuel injection pump housing and governor and put in position on the timing gear plate and oil manifold (3). Install the three nuts that hold the fuel injection pump housing to the timing gear plate and the two bolts that hold the governor housing to oil manifold (3).
After the fuel injection pump housing and governor are installed on the timing gear plate be sure the rack is free to move. The O-ring seal on the drive end of the fuel injection pump can hold the rack and prevent free movement of the rack. If the rack does not move freely remove the fuel injection pump housing and governor and check the O-ring seal on the drive end of the fuel injection pump housing.
4. Install the bolt and washer (4) as shown to hold the timing gear to the camshaft. Install washer (4) with the larger outside diameter toward the bolt head. Tighten the bolt finger tight only.5. Use the following procedure to put the No. 1 piston at top center on the compression stroke. No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures. The engine is seen from the flywheel end when direction of flywheel rotation is given. Do not turn the flywheel backward. a) Remove plug (5) from the flywheel housing and the breather from the valve cover.b) Turn the flywheel counterclockwise until a 3/8"-16 NC bolt (6) at least 2.5 in. long can be installed in the flywheel through the hole in
1. Be sure O-ring seals (1) and (2) are in position on the fuel injection pump housing and governor and put clean oil on the O-ring seals.2. Remove the cover on the fuel injection pump housing and install timing pin (A). Turn the camshaft until timing pin (A) goes in the groove in the camshaft as shown. 3. Fasten a strap and hoist to the fuel injection pump housing and governor and put in position on the timing gear plate and oil manifold (3). Install the three nuts that hold the fuel injection pump housing to the timing gear plate and the two bolts that hold the governor housing to oil manifold (3).
After the fuel injection pump housing and governor are installed on the timing gear plate be sure the rack is free to move. The O-ring seal on the drive end of the fuel injection pump can hold the rack and prevent free movement of the rack. If the rack does not move freely remove the fuel injection pump housing and governor and check the O-ring seal on the drive end of the fuel injection pump housing.
4. Install the bolt and washer (4) as shown to hold the timing gear to the camshaft. Install washer (4) with the larger outside diameter toward the bolt head. Tighten the bolt finger tight only.5. Use the following procedure to put the No. 1 piston at top center on the compression stroke. No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures. The engine is seen from the flywheel end when direction of flywheel rotation is given. Do not turn the flywheel backward. a) Remove plug (5) from the flywheel housing and the breather from the valve cover.b) Turn the flywheel counterclockwise until a 3/8"-16 NC bolt (6) at least 2.5 in. long can be installed in the flywheel through the hole in