101691-4210 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016914210 1156002481

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101691-4210 1016914210

ISUZU 1156002481 1156002481

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Buy INJECTION-PUMP ASSEMBLY 101691-4210 zexel genuine, new aftermarket engine parts with delivery

Service parts 101691-4210 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-3130

3. GOVERNOR 105470-0760

4. SUPPLY PUMP 105210-4251

5. AUTOM. ADVANCE MECHANIS 105612-0830

6. COUPLING PLATE 105662-0350

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-2010

11. Nozzle and Holder 9-15300-184-2

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105031-2600

14. NOZZLE

105000-1130

15. NOZZLE SET

Include in #1:

101691-4210 as INJECTION-PUMP ASSEMBLY

Include in #2:

104745-8040 as _

104745-8041

Cross reference number

ZEXEL 101691-4210 1016914210

ISUZU 1156002481 1156002481

Zexel num

Bosch num

Firm num

Name

101691-4210

1156002481 ISUZU

INJECTION-PUMP ASSEMBLY
DH100 *

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 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

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

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
----------

0000000901

F:Full load I:Idle S:Stop
----------

----------
a=6deg+-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
----------

Information:

Remove Fuel Transfer Pump
1. Remove fuel line (1) from the fuel transfer pump.2. Put caps in the fuel line openings to prevent fuel system contamination.3. Remove bolts (2), and remove fuel transfer pump (3). Check the condition of the O-ring seal on the fuel transfer pump. If necessary, make a replacement.Install Fuel Transfer Pump
1. Be sure O-ring seal (1) is in position on the fuel transfer pump. Put clean engine oil on the O-ring seal.2. Put fuel transfer pump (2) in position, and install the bolts that hold it in place.3. Remove the caps from the fuel line openings, and install fuel line (3).4. Prime the fuel system. See the Maintenance Guide for this procedure.Disassemble Fuel Transfer Pump
START BY:a. remove fuel transfer pump 1. Remove seal (1) from the fuel transfer pump.
Cover (2) is under spring tension. Remove the bolts that hold cover (2) slowly to prevent injury.
2. Remove bolts (3) and cover (2) from the housing. 3. Remove seals (4) and valve (5) from cover (2). 4. Remove spring (6) from the piston.
Mark the orientation of valve (8) as to its location in the housing.
5. Remove washer (7), valve (8) and the seal from the housing. 6. Remove piston (9) and sleeve (10) from the housing. 7. Remove seal (11) from sleeve (12). 8. Remove guide and tappet assembly (13) from the housing. 9. Remove seal (14) from guide (15).
If tappet (17) or the guide are damaged or worn, they must be replaced as a unit.
10. Remove ring (16) from tappet (17) and the tappet from guide (15). 11. Remove the bolts and cover (18) from the housing. 12. Remove seal (19) from cover (18). 13. Remove valve (20) from the housing if necessary.Assemble Fuel Transfer Pump
1. Install valve (2) in housing (1) as shown. 2. Put clean fuel on seal (4), and install it on cover (3).3. Install cover (3) on the housing.
The tappet and guide must be serviced as a unit.
4. Install tappet (6) in guide (5). Install ring (7) on tappet (6) to hold the tappet in the guide. 5. Put clean fuel on seal (8), and install it on guide and tappet assembly (9).6. Install guide and tappet assembly (9) in the housing as shown. 7. Put clean fuel on seal (10), and install it on sleeve (11).8. Install sleeve (11) in the housing. 9. Install piston (12) in the housing. 10. Install seal valve (14) and washer (13) in the housing as shown. Be sure valve (14) is the correct position in the housing. 11. Install spring (15) in the piston. 12. Install valve (18) in cover (16) as shown.13. Put clean fuel on seals (17), and put them in position on cover (16).14. Install cover (16) on the housing. 15. Put seal (19) in position on the fuel transfer pump.16. Install the fuel transfer pump on the fuel injection pump housing.END BY:a. install fuel transfer pump