Information injection-pump assembly
ZEXEL
101602-7480
1016027480
ISUZU
1156027950
1156027950
Rating:
Service parts 101602-7480 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-291-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101602-7480
as INJECTION-PUMP ASSEMBLY
Include in #2:
104748-1000
as _
Cross reference number
ZEXEL
101602-7480
1016027480
ISUZU
1156027950
1156027950
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
3.6
3.55
3.65
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
8.8
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
78.5
77.5
79.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.5+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
9.4
8.1
10.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)The torque control spring does not operate.
(3)Set idle sub-spring
(4)Main spring setting
----------
K=18
----------
----------
K=18
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(13deg)+-5deg b=(22deg)+-5deg
----------
----------
a=(13deg)+-5deg b=(22deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=38deg+-5deg b=46deg+-5deg
----------
----------
a=38deg+-5deg b=46deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of pump side coupling's threaded hole at No. 1 cylinder's beginning of injection.
(3)B.T.D.C.: aa
(4)-
----------
aa=20deg
----------
a=(10deg)
----------
aa=20deg
----------
a=(10deg)
Information:
GENERAL
1. Schematic
Schematic2. Specifications (standard) INSPECTION
Inspection points1. Water pump Check the impeller and shaft for rotation. If they do not rotate freely or have noise, replace the water pump assembly.
Checking water pump2. Thermostat (standard) Hang the thermostat in the pan of water as shown in the illustration. The thermostat must be below the surface of the water and its must be away from the sides of the pan. Heat the water uniformly in the pan and measure a temperature at which the valve starts opening and a temperature at which the valve lift (distance) is 8 mm (0.3 in.). Replace the thermostat if defective.
Water in the pan is hot. Any contact can cause severe burns.
Testing thermostat3. Thermoswitch (standard) Hang the thermoswitch in the pan of oil with its temperature sensing end below the surface of oil and measure the resistance while heating the oil as shown in the illustration. If the resistance is incorrect, replace the thermoswitch.
Oil in the pan is hot. Any contact can cause severe burns.
Testing thermoswitch4. Thermounit (standard) Hang the thermounit in the pan of antifreeze with its temperature sensing end below the surface of antifreeze and measure the resistance while heating the antifreeze as shown in the illustration. If the resistance is incorrect, replace the thermounit.
Antifreeze in the pan is hot. Any contact can cause severe burns.
Testing thermounit
1. Schematic
Schematic2. Specifications (standard) INSPECTION
Inspection points1. Water pump Check the impeller and shaft for rotation. If they do not rotate freely or have noise, replace the water pump assembly.
Checking water pump2. Thermostat (standard) Hang the thermostat in the pan of water as shown in the illustration. The thermostat must be below the surface of the water and its must be away from the sides of the pan. Heat the water uniformly in the pan and measure a temperature at which the valve starts opening and a temperature at which the valve lift (distance) is 8 mm (0.3 in.). Replace the thermostat if defective.
Water in the pan is hot. Any contact can cause severe burns.
Testing thermostat3. Thermoswitch (standard) Hang the thermoswitch in the pan of oil with its temperature sensing end below the surface of oil and measure the resistance while heating the oil as shown in the illustration. If the resistance is incorrect, replace the thermoswitch.
Oil in the pan is hot. Any contact can cause severe burns.
Testing thermoswitch4. Thermounit (standard) Hang the thermounit in the pan of antifreeze with its temperature sensing end below the surface of antifreeze and measure the resistance while heating the antifreeze as shown in the illustration. If the resistance is incorrect, replace the thermounit.
Antifreeze in the pan is hot. Any contact can cause severe burns.
Testing thermounit