Information injection-pump assembly
ZEXEL
101602-7551
1016027551
ISUZU
1156028591
1156028591
Rating:
Service parts 101602-7551 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
8.
_
9.
_
11.
Nozzle and Holder
8-94130-074-3
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}
15.
NOZZLE SET
Include in #1:
101602-7551
as INJECTION-PUMP ASSEMBLY
Include in #2:
104748-1250
as _
Cross reference number
ZEXEL
101602-7551
1016027551
ISUZU
1156028591
1156028591
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
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
47.5
46
49
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.9+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
12.2
10.8
13.6
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.
Injection quantity adjustment_03
Adjusting point
D
Rack position
13.5+-0.
1
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
121
111
131
Fixing the lever
*
Rack limit
*
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)RACK LIMIT: RAL
(4)Set idle sub-spring
(5)Main spring setting
(6)Rack difference between N = N1 and N = N2
----------
K=10 RAL=13.5+-0.1mm N1=1200r/min N2=700r/min
----------
----------
K=10 RAL=13.5+-0.1mm N1=1200r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(3deg)+-5deg b=(22deg)+-5deg
----------
----------
a=(3deg)+-5deg b=(22deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=46deg+-5deg b=52deg+-5deg
----------
----------
a=46deg+-5deg b=52deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(10deg)
----------
----------
a=(10deg)
Information:
In this manual, specifications, service standards, adjustment procedures, disassembly procedures, inspection procedures, and reassembly procedures for the engine are shown in groups. The contents of each group are listed in the index and at the beginning of that group. For instructions on operation and periodic inspection, refer to the operation manual. For instructions on ordering replacement parts, refer to the parts catalog. For information on the engine's structure and function, refer to relevant training material.Items Shown in this Manual
(1) Parts mentioned in the text and shown exploded views are numbered in their disassembly sequences.(2) Inspections to be preformed during disassembly are shown in
in the exploded views.(3) Service standards for inspection and repair operations are indicated at relevant places in the text and in a table in Group 2.(4) The sequences in which parts should be reassembled during reassembly operations are shown under reassembly drawings in this manner:
(5) The symbols and headings shown below are used in this manual to highlight particularly important and safety-critical instruction.
Indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.
Indicates a potentially hazardous situation which, if not avoided, can result in property damage.
Indicates important information or information which is useful for engine operation or maintenance.(6) With regard to tightening torques, points to which engine oil must be applied are labeled "Wet". Where there is no such indication, parts should be tightened in a dry condition.Terms Used in This Manual
Terms used in this manual are defined as follows:(1) Front and RearThe term "front" refers to the fan side of the engine, and the term "rear" applies to the flywheel side.(2) Left and RightThe term "left" and "right" apply to the sides of the engine as seen from the flywheel.(3) Service Standards* Standard ValueThis term indicates a designed nominal dimension, the designed dimension of a single part, the standard clearance between two parts after assembly, or a standard performance value for an assembly.* LimitThis term indicates a value beyond which a part is no longer usable in terms of performance and strength and must be repaired or replaced.
(1) Parts mentioned in the text and shown exploded views are numbered in their disassembly sequences.(2) Inspections to be preformed during disassembly are shown in
in the exploded views.(3) Service standards for inspection and repair operations are indicated at relevant places in the text and in a table in Group 2.(4) The sequences in which parts should be reassembled during reassembly operations are shown under reassembly drawings in this manner:
(5) The symbols and headings shown below are used in this manual to highlight particularly important and safety-critical instruction.
Indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.
Indicates a potentially hazardous situation which, if not avoided, can result in property damage.
Indicates important information or information which is useful for engine operation or maintenance.(6) With regard to tightening torques, points to which engine oil must be applied are labeled "Wet". Where there is no such indication, parts should be tightened in a dry condition.Terms Used in This Manual
Terms used in this manual are defined as follows:(1) Front and RearThe term "front" refers to the fan side of the engine, and the term "rear" applies to the flywheel side.(2) Left and RightThe term "left" and "right" apply to the sides of the engine as seen from the flywheel.(3) Service Standards* Standard ValueThis term indicates a designed nominal dimension, the designed dimension of a single part, the standard clearance between two parts after assembly, or a standard performance value for an assembly.* LimitThis term indicates a value beyond which a part is no longer usable in terms of performance and strength and must be repaired or replaced.