Information injection-pump assembly
BOSCH
9 400 619 642
9400619642
ZEXEL
101402-0980
1014020980
ISUZU
8943251110
8943251110
Rating:
Service parts 101402-0980 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-105-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 619 642
9400619642
ZEXEL
101402-0980
1014020980
ISUZU
8943251110
8943251110
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
1-3-4-2
Pre-stroke
mm
3.4
3.35
3.45
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
9.7
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
71.8
70.3
73.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.6+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6.6
9.4
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Set idle sub-spring
(3)Main spring setting
(4)Rack difference between N = N1 and N = N2
----------
K=15 N1=1200r/min N2=800r/min
----------
----------
K=15 N1=1200r/min N2=800r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=16deg+-5deg b=31deg+-5deg
----------
----------
a=16deg+-5deg b=31deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=4.5deg+-5deg b=53deg+-5deg
----------
----------
a=4.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=18deg
----------
a=(90deg)
----------
aa=18deg
----------
a=(90deg)
Information:
Crankshaft Turns Free Exhaust Smoke Can Be Seen While Starting
Cold Outside Temperatures ... It may be necessary to use starting aids, or warm engine oil or coolant, at temperatures below 10°F (-12°C).Air in Fuel System ... See PRIMING THE FUEL SYSTEM.Low Quality Fuel ... Drain a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, drain the tank and fill with a good quality fuel. Change the fuel filter and "prime". If there is no water in the fuel, using an outside supply of fuel, prime and start the engine. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel and prime the fuel system.Fuel Injection Timing Not Correct. *Valve Adjustment Not Correct ... Check and make necessary adjustment. See VALVE LASH ADJUSTMENT.Defective Fuel Nozzle(s) ... Replace the fuel nozzles.Low Compression ... See the topic MISFIRING AND RUNNING ROUGH.Exhaust Smoke Cannot Be Seen While Starting
No Fuel in Tank ... Check fuel level visually (do not use the fuel gauge only). Be sure tank selection valve is open to the tank with fuel in it. Be sure valve in fuel line between the tanks is open.No Fuel From Fuel Injection Pump ... Loosen one or more of the fuel injection line nuts at the cylinder heads. With ignition switch on and accelerator in the fuel on position, turn the engine with the starter to be sure there is no fuel from the fuel injection pump. To find the cause for no fuel, see the following information.Prime fuel system.Check solenoid by turning on ignition switch. You must hear a sound when the plunger opens. If no sound is heard, make sure there is battery voltage at the solenoid and that the voltage is no less than 8 volts (terminal voltage while cranking). If voltage is less than 8 volts, the problem is low charge in battery or defective wiring. If voltage is 8 or more volts, loosen the cap on the tee at the fuel filter and release the fuel pressure at the solenoid. If the solenoid now works, the fuel transfer pump is holding fuel pressure at the solenoid. Clean or install a new fuel transfer pump. If solenoid does not work when pressure is released, install a new solenoid.Check for a dirty fuel filter by checking fuel pressure at the fuel filter outlet while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2) check fuel pressure at the outlet of the fuel transfer pump. If fuel pressure at the outlet of the transfer pump is more than the fuel pressure at the fuel filter outlet, install a new fuel filter.Check for a defective fuel transfer pump by checking fuel pressure at the outlet of the fuel transfer pump while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2), clean the primary fuel filter
Cold Outside Temperatures ... It may be necessary to use starting aids, or warm engine oil or coolant, at temperatures below 10°F (-12°C).Air in Fuel System ... See PRIMING THE FUEL SYSTEM.Low Quality Fuel ... Drain a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, drain the tank and fill with a good quality fuel. Change the fuel filter and "prime". If there is no water in the fuel, using an outside supply of fuel, prime and start the engine. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel and prime the fuel system.Fuel Injection Timing Not Correct. *Valve Adjustment Not Correct ... Check and make necessary adjustment. See VALVE LASH ADJUSTMENT.Defective Fuel Nozzle(s) ... Replace the fuel nozzles.Low Compression ... See the topic MISFIRING AND RUNNING ROUGH.Exhaust Smoke Cannot Be Seen While Starting
No Fuel in Tank ... Check fuel level visually (do not use the fuel gauge only). Be sure tank selection valve is open to the tank with fuel in it. Be sure valve in fuel line between the tanks is open.No Fuel From Fuel Injection Pump ... Loosen one or more of the fuel injection line nuts at the cylinder heads. With ignition switch on and accelerator in the fuel on position, turn the engine with the starter to be sure there is no fuel from the fuel injection pump. To find the cause for no fuel, see the following information.Prime fuel system.Check solenoid by turning on ignition switch. You must hear a sound when the plunger opens. If no sound is heard, make sure there is battery voltage at the solenoid and that the voltage is no less than 8 volts (terminal voltage while cranking). If voltage is less than 8 volts, the problem is low charge in battery or defective wiring. If voltage is 8 or more volts, loosen the cap on the tee at the fuel filter and release the fuel pressure at the solenoid. If the solenoid now works, the fuel transfer pump is holding fuel pressure at the solenoid. Clean or install a new fuel transfer pump. If solenoid does not work when pressure is released, install a new solenoid.Check for a dirty fuel filter by checking fuel pressure at the fuel filter outlet while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2) check fuel pressure at the outlet of the fuel transfer pump. If fuel pressure at the outlet of the transfer pump is more than the fuel pressure at the fuel filter outlet, install a new fuel filter.Check for a defective fuel transfer pump by checking fuel pressure at the outlet of the fuel transfer pump while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2), clean the primary fuel filter