Information injection-pump assembly
ZEXEL
101602-7351
1016027351
ISUZU
1156025540
1156025540
Rating:
Service parts 101602-7351 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-250-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101602-7351
1016027351
ISUZU
1156025540
1156025540
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
1-5-3-6-
2-4
Pre-stroke
mm
3.4
3.35
3.45
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
82.5
81
84
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
4.9+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
11.5
10.2
12.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Do not adjust boost compensator spring.
(3)Set idle sub-spring
(4)Main spring setting
(5)Rack difference between N = N1 and N = N2
----------
K=9 N1=1100r/min N2=800r/min
----------
----------
K=9 N1=1100r/min N2=800r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(1deg)+-5deg b=(20deg)+-5deg
----------
----------
a=(1deg)+-5deg b=(20deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=46deg+-5deg
----------
----------
a=12deg+-5deg b=46deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=17deg
----------
a=(60deg)
----------
aa=17deg
----------
a=(60deg)
Information:
General Information
Fig. 1-Fuel Pump LocationThe fuel transfer pump is located on the right side of the engine as shown on (1, Fig. 1).Removal
Disconnect and plug fuel lines (2, Fig. 1) at pump.Remove attaching hardware.Repair
Airtex Fuel Transfer Pumps
Fig. 2-Airtex Fuel Transfer PumpTo remove or install primer lever, (1, Fig. 2) compress rocker arm lever (2). And pull primer lever out.Further disassembly of the transfer pump is not possible.A.C. Fuel Transfer Pumps
When disassembling, mark pump cover and pump body for easier reassembly.Test all parts for serviceability and replace, if necessary.When assembling the fuel pump, observe the following:
Fig. 3-A.C. Fuel Transfer PumpMake sure diaphragm (1, Fig. 3) is engaged in rocker arm (2).Before installing the pump cover (3), position diaphragm so that it is level by moving rocker arm. Hold lever in this position.Install pump cover and cover screws. However, turn in screws so that they just contact the washers. Operate rocker arm several times, then release with a snap to make sure that diaphragm will not be overstretched when in use. Tighten cover screws in a crosswise pattern.Corona (B.C.D.) Fuel Transfer Pump
When disassembling, mark pump cover and pump body for easier reassembly.
Fig. 4-Diaphragm RemovalDisconnect diaphragm by pressing it against flange (Fig. 4).
Fig. 5-Remove Valve Plate and FilterCarefully remove valve plate with filter from pump cover (Fig. 5).Check all parts for serviceability and replace, if necessary.When assembling the fuel pump, observe the following: Make sure diaphragm is engaged in rocker arm.Before installing the pump cover, position diaphragm so that it is level by moving rocker arm. Hold lever in this position.Install pump cover and cover screws. However, turn in screws so that they just contact the washers.Operate rocker arm several times, then release with a snap to make sure that diaphragm will not be overstretched when in use.Tighten cover screws in a crosswise pattern.Installation
Using a new gasket, attach transfer pump to cylinder block. Connect lines and bleed fuel system.
Fig. 1-Fuel Pump LocationThe fuel transfer pump is located on the right side of the engine as shown on (1, Fig. 1).Removal
Disconnect and plug fuel lines (2, Fig. 1) at pump.Remove attaching hardware.Repair
Airtex Fuel Transfer Pumps
Fig. 2-Airtex Fuel Transfer PumpTo remove or install primer lever, (1, Fig. 2) compress rocker arm lever (2). And pull primer lever out.Further disassembly of the transfer pump is not possible.A.C. Fuel Transfer Pumps
When disassembling, mark pump cover and pump body for easier reassembly.Test all parts for serviceability and replace, if necessary.When assembling the fuel pump, observe the following:
Fig. 3-A.C. Fuel Transfer PumpMake sure diaphragm (1, Fig. 3) is engaged in rocker arm (2).Before installing the pump cover (3), position diaphragm so that it is level by moving rocker arm. Hold lever in this position.Install pump cover and cover screws. However, turn in screws so that they just contact the washers. Operate rocker arm several times, then release with a snap to make sure that diaphragm will not be overstretched when in use. Tighten cover screws in a crosswise pattern.Corona (B.C.D.) Fuel Transfer Pump
When disassembling, mark pump cover and pump body for easier reassembly.
Fig. 4-Diaphragm RemovalDisconnect diaphragm by pressing it against flange (Fig. 4).
Fig. 5-Remove Valve Plate and FilterCarefully remove valve plate with filter from pump cover (Fig. 5).Check all parts for serviceability and replace, if necessary.When assembling the fuel pump, observe the following: Make sure diaphragm is engaged in rocker arm.Before installing the pump cover, position diaphragm so that it is level by moving rocker arm. Hold lever in this position.Install pump cover and cover screws. However, turn in screws so that they just contact the washers.Operate rocker arm several times, then release with a snap to make sure that diaphragm will not be overstretched when in use.Tighten cover screws in a crosswise pattern.Installation
Using a new gasket, attach transfer pump to cylinder block. Connect lines and bleed fuel system.