Information injection-pump assembly
BOSCH
9 400 613 977
9400613977
ZEXEL
101402-7650
1014027650
ISUZU
8972234270
8972234270
Rating:
Cross reference number
BOSCH
9 400 613 977
9400613977
ZEXEL
101402-7650
1014027650
ISUZU
8972234270
8972234270
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
1-3-4-2
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
8.5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
81
79.9
82.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6+-0.5
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
8.8
7.4
10.2
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
125
120
130
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
(4)Set idle sub-spring
(5)Main spring setting
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
D:Dead point
S:Stop
(1)Speed = aa (P mode)
(2)Speed = aa (HP mode)
----------
aa=1100r/min bb=1210r/min
----------
a=(22deg)+-5deg b=(14deg)+-5deg c=(21deg)+-5deg d=(13deg)+-3deg e=(4deg)+-5deg
----------
aa=1100r/min bb=1210r/min
----------
a=(22deg)+-5deg b=(14deg)+-5deg c=(21deg)+-5deg d=(13deg)+-3deg e=(4deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=13deg+-5deg b=53deg+-5deg
----------
----------
a=13deg+-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=9deg
----------
a=(100deg)
----------
aa=9deg
----------
a=(100deg)
Information:
TIMING MARKS2. Remove the plug from the timing pin hole in fuel injection pump housing and install timing pin (1).
TIMING PIN INSTALLED
1. FT887 Timing Pin (Fabricated Tool).3. Remove bolts (2) and tachometer drive assembly (3) from the fuel injection pump camshaft.
PUMP DRIVE GEAR
2. Bolts (three). 3. Tachometer drive assembly. 4. Drive gear.4. Remove the drive gear (4) from the fuel injection pump camshaft.
TIMING ADVANCE
5. Retaining screw. 6. Washer. 7. Automatic timing advance.5. Remove retaining screw (5), washer (6), and automatic timing advance (7) from the engine camshaft.6. Install puller (8), with spacer (10) over the shaft in the camshaft and spacer (9) on spacer (10) as shown and remove the gear from the camshaft.
REMOVING GEAR (Typical Example)
8. 1P2321 Puller. 9. 8S5579 Spacer. 10. 9S9155 Spacer.Install Camshaft Gear
1. Heat the gear to a temperature of approximately 400° F (204° C) before installing on the camshaft.
Do not head the gear with a torch. Do not heat the gear to a temperature of more than 600° F (315° C). Heating the gear with a torch or to a temperature of more than 600° F (315° C) may cause the two drive dowels for the automatic timing advance to loosen and come out of the gear.
TIMING MARKS2. Align slot in gear hub with the pin in the camshaft. Install the gear on the camshaft with timing mark on gear aligned with timing mark on crankshaft gear. Be sure the gear is completely seated against the shoulder of the camshaft.
Do not drive the gear on the camshaft. Serious damage can result to camshaft or camshaft thrust pin.
3. Align holes in weights with dowels in gear and install the automatic timing advance.4. Align pin (11) in washer (6) with hole (12) in camshaft and install washer (6).
INSTALLING WASHER
6. Washer. 11. Pin. 12. Hole.5. Install retaining screw (5) and tighten to 108 36 lb. in. (124.5 41.5 cm.kg). Stake screw (5) in two places.
Stake retaining screw (5) carefully. Heavy blows on washer or retaining screw can force the shaft extension too far into the camshaft and eliminate all end clearance.
STAKING SCREW (Typical Example)
5. Retaining screw.6. After retaining screw (5) is staked, the gear and weight assembly requires .003 to .027 in. (0.08 to 0.69 mm) end clearance to prevent binding against the washer, camshaft end, or camshaft gear.7. Put timing plate (14) on the engine and thread bolt (13) into the timing gear.
TIMING PLATE INSTALLED
13. Bolt. 14. 5P950 Timing Plate.8. Install drive gear (4) on the fuel injection pump camshaft with the holes in the position shown and the part number facing out. To be able to advance the timing adjustment without removing the front cover, position gear (4) in the direction of the arrow so the bolt holes in the fuel injection pump camshaft are off center as shown. The bolts must thread freely into the holes in the fuel injection pump camshaft.
GEAR INSTALLED
4. Drive gear.9. Install tachometer drive assembly (3) and tighten finger tight.10. Install bolts (2) and tighten the bolts