Information injection-pump assembly
ZEXEL
101491-0741
1014910741
ISUZU
8970930641
8970930641
Rating:
Service parts 101491-0741 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
101491-0741
1014910741
ISUZU
8970930641
8970930641
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
10.4
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
52
50.4
53.6
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
9.9+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
12.5
11.2
13.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.4)
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
52
51
53
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.
64.5
61.3
67.7
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=J48
----------
----------
T1=J48
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=5.5deg+-5deg b=34.5deg+-3deg
----------
----------
a=5.5deg+-5deg b=34.5deg+-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
1. Adjustment of the aneroid compensator itself and the adjustment after 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 (A) to obtain the performance shown in the graph (to obtain L1).
(3)Adjust the (D) spacer so that dimension L2 is obtained.
(4)As there is hysterisis, measure when the absolute pressure drops.
(5)Hysterisis must not exceed rack position = h1.
----------
N1=1050r/min L1=1.5+-0.5mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.4)mm Rb=R1-0.45mm P1=95.4+-5.3kPa(716+-40mmHg) P2=70.1+-0.7kPa(526+-5mmHg) Q1=52+-1cm3/1000st Q2=(40.7+-1.6)cm3/1000st
----------
N1=1050r/min L1=1.5+-0.5mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.4)mm Rb=R1-0.45mm P1=95.4+-5.3kPa(716+-40mmHg) P2=70.1+-0.7kPa(526+-5mmHg) Q1=52+-1cm3/1000st Q2=(40.7+-1.6)cm3/1000st
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:
Group 2
1 - 6I0347 Bracket2 - 7C6591 Clamp2 - 7C7747 Clamp2 - 4B4274 Washer2 - 9N3388 Screw1 - 6I4813 Clamp Kit1 - 8T1296 Washer2 - 5P4939 Screw1 - 9Y3357 Clamp1 - 1029228 Clamp AssemblyGroup 3
2 - 5P4939 Screw1 - 9Y3357 Clamp1 - 1029228 Clamp AssemblyAction Required
See the attached procedure.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Refer to the following instructions and illustrations. Replace the existing fuel lines and their related parts with the new fuel line groups.
To insure correct clamp locations, install left and right fuel line groups as assembled. However, if clamps are removed, mark locations to insure correct positions when reassembling.
On the 992C Wheel Loader, it is necessary to remove the 6N8322 Air Outlet Tube Assembly to be able to install the right bank fuel line group.
Tighten the fuel line clamp screws to a torque of 2.25 N m (20 lb in). Do not over tighten. Use a 6V6069 Torque Screwdriver or similar tool to tighten the screws.
Group 1 Procedure
1. Clean and paint the new 6I0361 and 7E3539 Fuel Line Groups before proceeding to the job site.A) "Tape Off" the number 3, 5, and 6 fuel lines in the area of the tower clamp. (See Illustration 1 - Part 4 of 5, Section C-C)B) Install 5F2807 Plastic Caps and 2F2990 Plastic Plugs on the ends of the fuel lines.C) Clean and paint the fuel line groups.D) After drying completely, remove the tape. Do not remove the plastic caps and plugs until the fuel lines are ready to be installed on the engine. Transport the fuel line groups in their original boxes.2. Remove all mounting bolts from the fuel line brackets at the aftercooler housing. Except for the tower clamp assembly, new mounting bolts and washers will be used. Keep the washers. The washers may be needed later as spacers.3. A) Disassemble the tower clamp assembly behind the fuel injection pump. The 9Y3356 Clamp and 9Y3359 Clamp As. that form the tower clamp will be reused. (See Illustration 1 - Part 4 of 5, Section C-C)B) Disconnect the 2 line clamps from the 9Y3361 Bracket (Front V Bracket).C) Disconnect the 6 line clamps from the 7E5779 Bracket (Large V Bracket).4. Disconnect all the fuel lines at the fuel injection pump and at the adaptors in the valve cover bases.5. A) Remove the left and right side fuel line groups as separate assemblies.B) Remove the 9Y3361 Bracket (Front V Bracket). Replace it with a new 6I0347 Bracket.6. Remove the plastic caps and plugs from the fuel lines. Set the new 6I0361 Fuel Lines Group (left side) and the new 7E3539 Fuel Lines Group (right side) in place and hand tighten the fuel nuts. (See Illustration 1 - Part 1 of 5). If any of the ends of the individual fuel lines are not square with the bonnets in the fuel injection pump or with the adaptors in the valve cover bases, gently bend the lines
1 - 6I0347 Bracket2 - 7C6591 Clamp2 - 7C7747 Clamp2 - 4B4274 Washer2 - 9N3388 Screw1 - 6I4813 Clamp Kit1 - 8T1296 Washer2 - 5P4939 Screw1 - 9Y3357 Clamp1 - 1029228 Clamp AssemblyGroup 3
2 - 5P4939 Screw1 - 9Y3357 Clamp1 - 1029228 Clamp AssemblyAction Required
See the attached procedure.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Refer to the following instructions and illustrations. Replace the existing fuel lines and their related parts with the new fuel line groups.
To insure correct clamp locations, install left and right fuel line groups as assembled. However, if clamps are removed, mark locations to insure correct positions when reassembling.
On the 992C Wheel Loader, it is necessary to remove the 6N8322 Air Outlet Tube Assembly to be able to install the right bank fuel line group.
Tighten the fuel line clamp screws to a torque of 2.25 N m (20 lb in). Do not over tighten. Use a 6V6069 Torque Screwdriver or similar tool to tighten the screws.
Group 1 Procedure
1. Clean and paint the new 6I0361 and 7E3539 Fuel Line Groups before proceeding to the job site.A) "Tape Off" the number 3, 5, and 6 fuel lines in the area of the tower clamp. (See Illustration 1 - Part 4 of 5, Section C-C)B) Install 5F2807 Plastic Caps and 2F2990 Plastic Plugs on the ends of the fuel lines.C) Clean and paint the fuel line groups.D) After drying completely, remove the tape. Do not remove the plastic caps and plugs until the fuel lines are ready to be installed on the engine. Transport the fuel line groups in their original boxes.2. Remove all mounting bolts from the fuel line brackets at the aftercooler housing. Except for the tower clamp assembly, new mounting bolts and washers will be used. Keep the washers. The washers may be needed later as spacers.3. A) Disassemble the tower clamp assembly behind the fuel injection pump. The 9Y3356 Clamp and 9Y3359 Clamp As. that form the tower clamp will be reused. (See Illustration 1 - Part 4 of 5, Section C-C)B) Disconnect the 2 line clamps from the 9Y3361 Bracket (Front V Bracket).C) Disconnect the 6 line clamps from the 7E5779 Bracket (Large V Bracket).4. Disconnect all the fuel lines at the fuel injection pump and at the adaptors in the valve cover bases.5. A) Remove the left and right side fuel line groups as separate assemblies.B) Remove the 9Y3361 Bracket (Front V Bracket). Replace it with a new 6I0347 Bracket.6. Remove the plastic caps and plugs from the fuel lines. Set the new 6I0361 Fuel Lines Group (left side) and the new 7E3539 Fuel Lines Group (right side) in place and hand tighten the fuel nuts. (See Illustration 1 - Part 1 of 5). If any of the ends of the individual fuel lines are not square with the bonnets in the fuel injection pump or with the adaptors in the valve cover bases, gently bend the lines