Information injection-pump assembly
ZEXEL
101491-0557
1014910557
ISUZU
8970439731
8970439731
Rating:
Service parts 101491-0557 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97021-703-1
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
ZEXEL
101491-0557
1014910557
ISUZU
8970439731
8970439731
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
3.85
3.8
3.9
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
12.4
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
58.8
57.2
60.4
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
325
325
325
Average injection quantity
mm3/st.
13.3
12
14.6
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(12.4)
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
58.8
57.8
59.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.5
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
77.1
73.1
81.1
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
92
92
124
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1530--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1480
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=G20 N1=100r/min
----------
----------
T1=G20 N1=100r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Set the idle side stopper bolt so that speed = bb and rack position = cc (at delivery).
(3)Stopper bolt set position 'H'
----------
aa=50mm bb=100r/min cc=(12.4)mm
----------
a=(23.5deg) b=27.5deg+-5deg c=(38deg)+-3deg
----------
aa=50mm bb=100r/min cc=(12.4)mm
----------
a=(23.5deg) b=27.5deg+-5deg c=(38deg)+-3deg
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=3.85+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131154-1820 ST=A260 L1=1mm L2=3.85+-0.05mm a1=+-14% a2=+-2.5%
----------
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:
New cylinder blocks have been introduced on the 4.236 engine for the Backhoe Loaders. They have a larger cylinder liner parent bore diameter. The outside diameter of the cylinder liner is also larger. There is no longer a flame ring on the liner. The change became effective with engine serial number LD70178U106654N. The engine serial number is located above the fuel injection pump on the block.(1) Outside diameter of cylinder liner. Earlier engines with thin wall liners: Production liner ... 103.238 to 103.264 mm (4.0645 to 4.0655 in)Service liner ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners: Production liner ... 104.254 to 104.280 mm (4.1045 to 4.1055 in)Service liner ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)(2) Inside diameter of cylinder liner: Production liner ... 98.48 to 98.50 mm (3.877 to 3.878 in)Service liner ... 98.50 to 98.53 mm (3.878 to 3.879 in)Maximum diameter wear (when new liners are needed) ... 0.20 mm (.008 in)Transition fit of service liner in cylinder block ... 0.03 mm ( .001 in)Length of cylinder liner ... 227.10 to 227.43 mm (8.941 to 8.954 in)(3) Liner (flange) projection [do not measure from flame ring (if so equipped)] ... 0.10 mm (.004 in) above to ... 0.10 mm (.004 in) below Flange thickness of cylinder liner ... 3.81 to 3.86 mm (.150 to .152 in)Flange projection ... 0.10 mm (.004 in) above to ... 0.10 mm (.004 in) below face of cylinder block(4) Diameter of parent bore in cylinder block for liner: Earlier engines with thin wall liners ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)Depth of recess for cylinder liner flange ... 3.81 to 3.91 mm (.150 to .154 in)(5) Diameter of bore in cylinder block for camshaft No. 1 front bearing [has only front bearing (6)] ... 55.563 to 55.593 mm (2.1875 to 2.1887 in) Diameter of bearing bore for camshaft ... 50.800 to 50.843 mm (2.0000 to 2.0017 in)Diameter of bore for No. 2 journal ... 50.55 to 50.592 mm (1.990 to 1.9918 in)Diameter of bore for No. 3 journal ... 50.04 to 50.084 mm (1.970 to 1.9718 in)Clearance of camshaft in bore:Front (No. 1) ... 0.064 to 0.114 mm (.0025 to .0045 in)No. 2, No. 3 ... 0.064 to 0.135 mm (.0025 to .0053 in)Camshaft end play ... 0.10 to 0.41 mm (.004 to .016 in)Maximum permissible end play (worn) ... 0.51 mm (.020 in)(7) Diameter of bores in cylinder block for main bearings ... 80.42 to 80.44 mm (3.166 to 3.167 in)(8) Torque for main bearing cap bolts ... 245 N m (180 lb ft).Total height of cylinder block between top and bottom faces (not shown) ... 441.12 to 441.33 mm (17.367 to 17.375 in)