Information injection-pump assembly
ZEXEL
101691-4200
1016914200
ISUZU
1156000611
1156000611
Rating:
Service parts 101691-4200 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
9-15300-184-2
12.
Open Pre:MPa(Kqf/cm2)
9.8{100}
15.
NOZZLE SET
Include in #1:
101691-4200
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
101691-4200
1016914200
ISUZU
1156000611
1156000611
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
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
1-4-2-6-
3-5
Pre-stroke
mm
2.2
2.15
2.25
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 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
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
13
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
103.5
101.2
105.8
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
13
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
115.5
112
119
Max. variation between cylinders
%
0
-3
3
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
6.5+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
10.7
8.4
13
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Timer adjustment
Pump speed
r/min
400+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
600
Advance angle
deg.
0.6
0.1
1.1
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
1.4
0.9
1.9
Timer adjustment_04
Pump speed
r/min
1150
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)Set the load lever's stop position so that R = aa (N = 0).
(3)RACK LIMIT: RAL
----------
DL=6-0.2mm aa=6mm RAL=13+0.2mm
----------
----------
DL=6-0.2mm aa=6mm RAL=13+0.2mm
----------
0000000901
F:Full load
I:Idle
S:Stop
----------
----------
a=4deg+-5deg b=6deg+-5deg c=46deg+-3deg
----------
----------
a=4deg+-5deg b=6deg+-5deg c=46deg+-3deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=275r/min Ra=6.5mm
----------
----------
N1=275r/min Ra=6.5mm
----------
Information:
START BY:a. remove valve coversb. remove fuel injection lines 1. Use tool (A) and a 5P328 crowfoot wrench (7/8") to loosen the fuel injection line nut at the nozzle end.
Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzles turn in the body.
2. Use tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (1). Install plugs in the fuel injection nozzles. 3. Remove the nut that holds the adapters to the cylinder head assembly. Remove fuel injection line adapters (2).Install Fuel Injection Line Adapters
1. Check the condition of O-ring seal (1) on fuel injection line adapter (2) for damage. Make a replacement if necessary.2. Lubricate O-ring seal (1) with clean engine oil. Install fuel injection line adapter (2). Tighten the retaining nut to a torque of 13.6 2.7 N m (10 2 lb.ft.). 3. Check the condition of the O-ring seal on inner fuel line (3) for damage, and make a replacement if necessary. Install inner fuel line (3).
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzles turn in the body.
4. Use tooling (A) to tighten the inner fuel line nuts to a torque of 40 7 N m (30 5 lb.ft.).END BY:a. install fuel injection linesb. install valve covers
Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzles turn in the body.
2. Use tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (1). Install plugs in the fuel injection nozzles. 3. Remove the nut that holds the adapters to the cylinder head assembly. Remove fuel injection line adapters (2).Install Fuel Injection Line Adapters
1. Check the condition of O-ring seal (1) on fuel injection line adapter (2) for damage. Make a replacement if necessary.2. Lubricate O-ring seal (1) with clean engine oil. Install fuel injection line adapter (2). Tighten the retaining nut to a torque of 13.6 2.7 N m (10 2 lb.ft.). 3. Check the condition of the O-ring seal on inner fuel line (3) for damage, and make a replacement if necessary. Install inner fuel line (3).
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzles turn in the body.
4. Use tooling (A) to tighten the inner fuel line nuts to a torque of 40 7 N m (30 5 lb.ft.).END BY:a. install fuel injection linesb. install valve covers