Information injection-pump assembly
ZEXEL
101602-7520
1016027520
ISUZU
1156028070
1156028070
Rating:
Service parts 101602-7520 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-199-2
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}
15.
NOZZLE SET
Include in #1:
101602-7520
as INJECTION-PUMP ASSEMBLY
Include in #2:
104748-1080
as _
Cross reference number
ZEXEL
101602-7520
1016027520
ISUZU
1156028070
1156028070
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
9.8
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
65.6
64.6
66.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7+-0.5
Pump speed
r/min
340
340
340
Average injection quantity
mm3/st.
7.5
6.2
8.8
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)Tolerance for racks not indicated: +-0.05mm.
(3)Set idle sub-spring
(4)Main spring setting
(5)Rack difference between N = N1 and N = N2
----------
K=16 N1=1200r/min N2=700r/min
----------
----------
K=16 N1=1200r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=25deg+-5deg b=121deg+-5deg
----------
----------
a=25deg+-5deg b=121deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=12deg+-5deg b=46deg+-5deg
----------
----------
a=12deg+-5deg b=46deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'C' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=20deg
----------
a=(90deg)
----------
aa=20deg
----------
a=(90deg)
Information:
2. Removing Accessories
(1) Removing Fan(a) Reduce the tension applied by the tension pulley by pushing the alternator toward the engine, then remove the water pump drive belt (1).(b) Remove the fan mounting bolts (2), then remove the fan (3).(c) Remove the water pump pulley (4), which was previously retained by the fan mounting bolts (2).(2) Removing Thermostat FittingRemove the water outlet fitting (1), then remove the thermostat (2), thermostat fitting (3), water joint (4), and temperature joint (5) in that sequence. (3) Removing Exhaust and Intake Manifolds(a) Remove the exhaust manifold mounting bolts, then remove the exhaust manifold (1) and the gasket (2).(b) Remove the intake manifold mounting bolts, then remove the intake manifold (3) and the gasket (4). When refitting the manifolds, fit each gasket with the side marked "MANIFOLD" facing the manifold. (4) Removing Water PumpRemove the water pump mounting bolts, then remove the water pump (1). (5) Removing Alternator(a) Disconnect the battery cables.(b) Disconnect the lead from terminal B at the rear of the alternator.(c) Remove the alternator connector.(d) Loosen the alternator brace bolt (1) and support bolt (2), then push the alternator toward the engine and remove the fan belt.(e) Remove the alternator. (6) Removing Starter(a) Disconnect the battery's (-) and (+) terminals in that sequence.(b) Disconnect the start wiring (1).(c) Remove the starter's two mounting bolts (2), then remove the starter (3). (7) Removing Oil Filter(a) The oil filter (2) must be replaced every 100 hours of use.(b) Remove the oil filter using a filter wrench (1). (8) Removing Fuel Filter(a) Remove the fuel pipe (1) that leads from the fuel tank and the fuel pipe (2) that leads to the fuel pump.(b) Remove the fuel filter (3) from the engine. (9) Removing Fuel Pipes(a) Remove the clamps from the four fuel pipes (1), then disconnect the fuel pipes from the engine and from the injection pump.(b) Remove the joints and clips from the fuel hose (2), then disconnect the fuel hose from the injector holders.
To keep dirt out of the fuel system, fit rubber caps over the parts of the injection pump and injector inlet connectors from which the injection pipes are disconnected.
(10) Removing Injection Pump
1 Fuel hose2 Fuel pipe3 Tie rod cover4 Tie rod spring5 Tie rod6 Injection pump7 Adjustment shim8 Control rack pin(a) Remove the tie rod cover (3).
Removing tie rod cover(b) Using long-nosed pliers, remove the tie rod spring (4) from the control rack pin (8) and from the governor lever pin.(c) Remove the tie rod (5).
Removing tie rod(d) Remove the injection pump (6) and the adjustment shim (7).
Removing injection pump(11) Removing Oil PumpRemove the oil pump's four mounting bolts, then remove the oil pump (1). (12) Removing InjectorDisconnect the fuel injection pipe (1) and the fuel hose (2) before removing the injector (3). 3. Refitting Accessories
3.1 General PointsRefit accessories by following the removal procedures in reverse. After refitting accessories, perform the following operations:(1) Pour the specified amount of engine oil into the engine.(2) Pour coolant into the cooling
(1) Removing Fan(a) Reduce the tension applied by the tension pulley by pushing the alternator toward the engine, then remove the water pump drive belt (1).(b) Remove the fan mounting bolts (2), then remove the fan (3).(c) Remove the water pump pulley (4), which was previously retained by the fan mounting bolts (2).(2) Removing Thermostat FittingRemove the water outlet fitting (1), then remove the thermostat (2), thermostat fitting (3), water joint (4), and temperature joint (5) in that sequence. (3) Removing Exhaust and Intake Manifolds(a) Remove the exhaust manifold mounting bolts, then remove the exhaust manifold (1) and the gasket (2).(b) Remove the intake manifold mounting bolts, then remove the intake manifold (3) and the gasket (4). When refitting the manifolds, fit each gasket with the side marked "MANIFOLD" facing the manifold. (4) Removing Water PumpRemove the water pump mounting bolts, then remove the water pump (1). (5) Removing Alternator(a) Disconnect the battery cables.(b) Disconnect the lead from terminal B at the rear of the alternator.(c) Remove the alternator connector.(d) Loosen the alternator brace bolt (1) and support bolt (2), then push the alternator toward the engine and remove the fan belt.(e) Remove the alternator. (6) Removing Starter(a) Disconnect the battery's (-) and (+) terminals in that sequence.(b) Disconnect the start wiring (1).(c) Remove the starter's two mounting bolts (2), then remove the starter (3). (7) Removing Oil Filter(a) The oil filter (2) must be replaced every 100 hours of use.(b) Remove the oil filter using a filter wrench (1). (8) Removing Fuel Filter(a) Remove the fuel pipe (1) that leads from the fuel tank and the fuel pipe (2) that leads to the fuel pump.(b) Remove the fuel filter (3) from the engine. (9) Removing Fuel Pipes(a) Remove the clamps from the four fuel pipes (1), then disconnect the fuel pipes from the engine and from the injection pump.(b) Remove the joints and clips from the fuel hose (2), then disconnect the fuel hose from the injector holders.
To keep dirt out of the fuel system, fit rubber caps over the parts of the injection pump and injector inlet connectors from which the injection pipes are disconnected.
(10) Removing Injection Pump
1 Fuel hose2 Fuel pipe3 Tie rod cover4 Tie rod spring5 Tie rod6 Injection pump7 Adjustment shim8 Control rack pin(a) Remove the tie rod cover (3).
Removing tie rod cover(b) Using long-nosed pliers, remove the tie rod spring (4) from the control rack pin (8) and from the governor lever pin.(c) Remove the tie rod (5).
Removing tie rod(d) Remove the injection pump (6) and the adjustment shim (7).
Removing injection pump(11) Removing Oil PumpRemove the oil pump's four mounting bolts, then remove the oil pump (1). (12) Removing InjectorDisconnect the fuel injection pipe (1) and the fuel hose (2) before removing the injector (3). 3. Refitting Accessories
3.1 General PointsRefit accessories by following the removal procedures in reverse. After refitting accessories, perform the following operations:(1) Pour the specified amount of engine oil into the engine.(2) Pour coolant into the cooling