Information injection-pump assembly
ZEXEL
101431-4150
1014314150
ISUZU
8943620980
8943620980
Rating:
Service parts 101431-4150 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-039-1
12.
Open Pre:MPa(Kqf/cm2)
11.8{120}
15.
NOZZLE SET
Cross reference number
ZEXEL
101431-4150
1014314150
ISUZU
8943620980
8943620980
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
2.25
2.2
2.3
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.5
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
42
41
43
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.6+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6.9
9.1
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.
Timer adjustment
Pump speed
r/min
500+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
1
0.5
1.5
Timer adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
2
1.2
2.7
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
4.5
3.9
4.9
Timer adjustment_05
Pump speed
r/min
-
Advance angle
deg.
6
6
6
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=17deg+-5deg b=32deg+-5deg
----------
----------
a=17deg+-5deg b=32deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=36.5deg+-5deg b=53deg+-5deg
----------
----------
a=36.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Gear mark Z for the No. 4 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(60deg)
----------
aa=14deg
----------
a=(60deg)
Information:
1. Drain the coolant from the radiator. 2. Remove bolts (1) and grill (2). 3. Remove bolts (5) and fan guard (3). Remove bolts (6) and support bracket (4). Remove the enclosure group top panel (7).4. Remove the bolts holding the enclosure group side panels. Remove the side panels.5. Loosen the hose clamps on the upper and lower radiator hoses. Disconnect the radiator hoses from the radiator. 6. Use tooling (A) and attach a hoist to radiator (8). Remove the lower bolts holding the radiator to the base. Remove radiator (8). The weight of the radiator is 73 kg (161 lb.). The following steps are for the installation of the radiator.7. Use a hoist to install the radiator on the base. Install the bolts. Remove the hoist and tooling (A) from the radiator.8. Connect the upper and lower radiator hoses to the radiator. Tighten the hose clamps.9. Install the enclosure group side panels.10. Install the enclosure group top panel. Install the grill and the fan guard.11. Fill the radiator with coolant to the correct level. See the Maintenance Manual.Remove And Install Radiator And Radiator Guard (Prime)
1. Drain the coolant from the radiator. 2. Loosen hose clamps (4) and (5). Disconnect tube (1) from hose (6). Rotate tube (1) 180° for clearance. Remove bolts (2) from support arms (3). 3. Remove eight bolts (7) holding fan guard (8) to the radiator guard. 4. Install tool (A) and a hoist to the radiator. 5. Remove four bolts (10) that fasten the lower radiator elbow to the radiator. Separate the elbow from the radiator. Remove bolt (11) from the crankcase vent hose clamp.Remove four mounting bolts (9). Remove the radiator and radiator guard. The weight of the radiator and radiator guard is 250 Kg (550 lb.). The following steps are for the installation of the radiator and radiator guard.6. Use a hoist to put the radiator and radiator guard in position on the base. Install four mounting bolts (9). Remove the hoist and tool (A).7. Install the gasket and lower radiator elbow (12) to the radiator. Install bolts (10). Install bolt (11) and the clamp to hold the crankcase vent hose in place.8. Install bolts (7) to hold fan guard (8) in position.9. Connect tube (1) to hose (6) and tighten hose clamps (4) and (5). Install bolts (2) to secure control arms (3) to the radiator guard.10. Fill the radiator with coolant to the correct level. See the Maintenance Manual.Disassemble And Assemble Radiator
Start By:a. remove radiator and radiator guard **The radiator can be disassembled and assembled without removing the radiator and guard. 1. Remove eighteen bolts (2) and remove four plates (4). Remove four bolts, block off plate (1) and the gasket. Remove four bolts, upper radiator hose adapter (3) and the gasket. 2. Loosen four bolts (7). Disconnect tube assemblies (5) and (8). Remove four bolts (9) and remove coolant level switch if applicable. 3. Remove eleven bolts (11) and remove overflow tube (10), crankcase vent tube clamp (13)
1. Drain the coolant from the radiator. 2. Loosen hose clamps (4) and (5). Disconnect tube (1) from hose (6). Rotate tube (1) 180° for clearance. Remove bolts (2) from support arms (3). 3. Remove eight bolts (7) holding fan guard (8) to the radiator guard. 4. Install tool (A) and a hoist to the radiator. 5. Remove four bolts (10) that fasten the lower radiator elbow to the radiator. Separate the elbow from the radiator. Remove bolt (11) from the crankcase vent hose clamp.Remove four mounting bolts (9). Remove the radiator and radiator guard. The weight of the radiator and radiator guard is 250 Kg (550 lb.). The following steps are for the installation of the radiator and radiator guard.6. Use a hoist to put the radiator and radiator guard in position on the base. Install four mounting bolts (9). Remove the hoist and tool (A).7. Install the gasket and lower radiator elbow (12) to the radiator. Install bolts (10). Install bolt (11) and the clamp to hold the crankcase vent hose in place.8. Install bolts (7) to hold fan guard (8) in position.9. Connect tube (1) to hose (6) and tighten hose clamps (4) and (5). Install bolts (2) to secure control arms (3) to the radiator guard.10. Fill the radiator with coolant to the correct level. See the Maintenance Manual.Disassemble And Assemble Radiator
Start By:a. remove radiator and radiator guard **The radiator can be disassembled and assembled without removing the radiator and guard. 1. Remove eighteen bolts (2) and remove four plates (4). Remove four bolts, block off plate (1) and the gasket. Remove four bolts, upper radiator hose adapter (3) and the gasket. 2. Loosen four bolts (7). Disconnect tube assemblies (5) and (8). Remove four bolts (9) and remove coolant level switch if applicable. 3. Remove eleven bolts (11) and remove overflow tube (10), crankcase vent tube clamp (13)