Information injection-pump assembly
ZEXEL
101491-0670
1014910670
ISUZU
8970480480
8970480480
Rating:
Service parts 101491-0670 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97119-858-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101491-0670
1014910670
ISUZU
8970480480
8970480480
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
3.2
3.15
3.25
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
10.6
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
56.4
54.8
58
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
-
Rack position
9.7+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
8
6.5
9.5
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(10.6)
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
56.4
55.4
57.4
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.15
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
67.7
64.5
70.9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
78.5
62.5
94.5
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1425--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1375
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1750
Advance angle
deg.
5
4.5
5.5
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.
----------
T1=G35
----------
----------
T1=G35
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=5.5deg+-5deg b=36deg+-3deg
----------
----------
a=5.5deg+-5deg b=36deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=45deg+-5deg b=29deg+-5deg
----------
----------
a=45deg+-5deg b=29deg+-5deg
0000001501 ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
(D) Cover
1. Aneroid compensator unit adjustment
(1)Select the push rod 2 to obtain L2.
(2)Screw in (A) to obtain L1.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
(3)As there is hysterisis, measure when the absolute pressure drops.
(4)Hysterisis must not exceed rack position = h1.
----------
N1=1050r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.6)mm Rb=R1-0.45mm Pa=95.4+-5.3kPa(716+-40mmHg) Pb=526+-0.7kPa(526+-5mmHg) Q1=56.4+-1cm3/1000st Q2=(43)+-1.6cm3/1000st
----------
N1=1050r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.6)mm Rb=R1-0.45mm Pa=95.4+-5.3kPa(716+-40mmHg) Pb=526+-0.7kPa(526+-5mmHg) Q1=56.4+-1cm3/1000st Q2=(43)+-1.6cm3/1000st
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=17deg
----------
a=(90deg)
----------
aa=17deg
----------
a=(90deg)
Information:
Illustration 23. (2) 141-6737 Adjustable Microgauge.
(7) Top of the 3P-1542 Barrel. (8) 141-6727 Calibration Pump Assembly.1. Place the 141-6737 Adjustable Microgauge on top of the 3P-1542 Barrel of the 141-6727 Calibration Pump Assembly.2. When starting to torque 124-5932 Lever Assemblies, the difference between the face of the 141-6730 Plunger and the 2N-2658 Bolt is about 0.03 mm (.001 in). By setting the 141-6737 Adjustable Microgauge (2) on top of the 141-6727 Calibration Pump Assembly (8), the 141-6737 Plunger can be positioned 25.40 mm (.001 in) above the face of the 3P-1542 Barrel (7).
Illustration 24. (9) 2N-2658 Bolt. (10) 124-5940 Shutoff Lever.3. As the 2N-2658 Bolt (9) is torqued, the 141-6730 Plunger will move down flush with the 3P-1542 Barrel (7) or will be very close to being flush. The calibration can begin from this point. The 2N-2658 Bolts must freely turn in and out of the 124-5940 Shutoff Levers (10) because the calibration depends on where the head of the 2N-2658 Bolt (9) first begins to clamp the 124-5940 Shutoff Lever for the starting point of the calibration.End Play Adjustment
1. In order to save time, use two torque wrenches (color-coding is convenient for distinguishing between the two wrenches). Set one torque wrench to 1.7 N m (15 lb in) and the second torque wrench to N m (35 lb in).
Illustration 25. (1) 124-5941 Shaft. (2) 4N-1826 Dowel on one end of the HSMFS Injection Pump Group. (3) 126-7232 Dowels.2. Adjust the end play in the 124-5941 Shaft. The SMFS 109-0324 Governor And Fuel Injection Pump Group had the dowel in the middle of the sleeve and a large amount of end play in the shaft was acceptable. Now that the 126-7232 Dowels (3) are between two 124-5934 Sleeves, the amount of end play is important. It is necessary that an adjustment be performed to minimize the amount of end play in the 124-5941 Shaft (1).3. The 126-7232 Dowels (3) are located between two 124-5934 Sleeves. Set the 126-7232 Dowels between 0.25 to 0.40 mm (.010 to .016 in) by tapping in the 4N-1826 Dowels (2) until the desired end play is achieved.* With the 1.7 N m (15 lb in) torque wrench, torque the 2N-2658 Bolts to 1.7 N m (15 lb in).* Then use the 4 N m (35 lb in) torque wrench to torque the 2N-2658 Bolts to 3.4 N m (30 lb in) in order to calibrate within specifications.Calibrating the 124-5932 Lever Assemblies.
Illustration 26. Calibrating the 124-5932 Lever Assemblies.
(1) 2N-2658 Bolts. (2) 124-5940 Shutoff Lever.1. Begin with the first 2N-2658 Bolt (1) and turn it until it just begins to clamp (feels snug) on the 124-5940 Shutoff Lever (2).2. Move to the other side and turn the second 2N-2658 Bolt (1) until just begins to clamp (feels snug).* Alternate between sides and tighten each 2N-2658 Bolt about 15 degrees each time.
Illustration 27. View of the HSMFS Injection Pump Group.
(3) Top of the 141-6730 Plunger shown flush with the 3P-1542 Barrel (4).3. Continue until the torque