Information injection-pump assembly
BOSCH
9 400 612 936
9400612936
ZEXEL
101402-8021
1014028021
ISUZU
8973187611
8973187611
Rating:
Service parts 101402-8021 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97211-280-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 612 936
9400612936
ZEXEL
101402-8021
1014028021
ISUZU
8973187611
8973187611
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
131424-0820
Overflow valve opening pressure
kPa
127
127
127
Overflow valve opening pressure
kgf/cm2
1.3
1.3
1.3
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
3.5
3.45
3.55
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
9.1
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
72.5
71.5
73.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
10
8
12
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
10.1++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
105
105
115
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)Idle sub spring setting: L1.
----------
K=8 L1=5.7-0.2mm
----------
----------
K=8 L1=5.7-0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa
(2)Stopper bolt setting
(3)When pump speed set at bb
----------
aa=900r/min bb=750r/min
----------
a=0deg+-5deg b=15deg+-5deg c=5deg+-5deg
----------
aa=900r/min bb=750r/min
----------
a=0deg+-5deg b=15deg+-5deg c=5deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=3.5deg+-5deg b=53deg+-5deg
----------
----------
a=3.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'W' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=2deg
----------
a=(200deg)
----------
aa=2deg
----------
a=(200deg)
Information:
start by:a) remove timing gear cover and oil pumpb) remove valve liftersc) remove turbocharger 1. Remove the plug from the fuel injection pump housing and install timing pin (A).2. While the crankshaft is turned clockwise (as seen from the front of the engine), push on tool (A) until it slides into the groove (slot) in the fuel injection pump camshaft.3. Remove the tachometer drive adapter shaft (1). 4. Install tooling (B) into the camshaft drive gear for the fuel injection pump. Turn both bolts evenly until the drive gear is free of the shaft. Remove tooling (B). 5. Remove thrust pin (2) that holds the camshaft in place from the rear of the cylinder block. 6. Remove the camshaft (3) and gears from the cylinder block as a unit. Be careful not to cause damage to the camshaft bearing or journals. The camshaft gear can be removed from the camshaft if a replacement is necessary. See the topic CAMSHAFT in the RECONDITIONING PROCEDURES.Install Camshaft And Gears
1. Install the camshaft gear on the camshaft if it was removed. Heat the gear to a maximum temperature of 315°C (600°F). Put the gear in position on the camshaft. Put clean engine oil on the camshaft lobes and journals. Install camshaft (1) and the gears as a unit. Make sure the timing marks on the crankshaft gear and camshaft gear are in alignment. 2. Install the thrust pin. Tighten the pin to a torque of 45 7 N m (35 5 lb.ft.).3. Put gear (3) in position and install tachometer drive adapter shaft (2). Tighten the shaft to the correct torque. For the correct torque, see the topic DRIVE GEAR FOR THE INJECTION PUMP in the SPECIFICATIONS.4. After valve lifters and timing gear cover have been installed, check the timing as follows: a) Remove timing pin (A).b) Turn the crankshaft clockwise as seen from the front of the engine approximately 1/2 turn. Install timing pin (A) again.c) While turning the crankshaft clockwise, push on timing pin (A) until it slides into the groove (slot) in the fuel injection pump camshaft. d) Remove the plug from the timing hole in the front cover and install a 5/16"-18 NC bolt (4) 2 1/2 in. long. The cover bolt from hole (5) can be used. Turn the crankshaft clockwise until bolt (4) can be installed into the timing gear and is in the center of the timing hole. The camshaft for the fuel injection pump is now in correct time with the engine.e) Remove the bolt and install the plug. Remove timing pin (A) and install the plug. If the bolt can not be installed in the hole of camshaft gear, the timing must be corrected as follows: a) With timing pin (A) installed, remove the tachometer drive adapter housing and shaft.b) Loosen the gear from the fuel injection pump camshaft. Turn the crankshaft clockwise approximately two full turns until bolt (4) can be installed. Install the bolt.c) Install tachometer drive adapter shaft
1. Install the camshaft gear on the camshaft if it was removed. Heat the gear to a maximum temperature of 315°C (600°F). Put the gear in position on the camshaft. Put clean engine oil on the camshaft lobes and journals. Install camshaft (1) and the gears as a unit. Make sure the timing marks on the crankshaft gear and camshaft gear are in alignment. 2. Install the thrust pin. Tighten the pin to a torque of 45 7 N m (35 5 lb.ft.).3. Put gear (3) in position and install tachometer drive adapter shaft (2). Tighten the shaft to the correct torque. For the correct torque, see the topic DRIVE GEAR FOR THE INJECTION PUMP in the SPECIFICATIONS.4. After valve lifters and timing gear cover have been installed, check the timing as follows: a) Remove timing pin (A).b) Turn the crankshaft clockwise as seen from the front of the engine approximately 1/2 turn. Install timing pin (A) again.c) While turning the crankshaft clockwise, push on timing pin (A) until it slides into the groove (slot) in the fuel injection pump camshaft. d) Remove the plug from the timing hole in the front cover and install a 5/16"-18 NC bolt (4) 2 1/2 in. long. The cover bolt from hole (5) can be used. Turn the crankshaft clockwise until bolt (4) can be installed into the timing gear and is in the center of the timing hole. The camshaft for the fuel injection pump is now in correct time with the engine.e) Remove the bolt and install the plug. Remove timing pin (A) and install the plug. If the bolt can not be installed in the hole of camshaft gear, the timing must be corrected as follows: a) With timing pin (A) installed, remove the tachometer drive adapter housing and shaft.b) Loosen the gear from the fuel injection pump camshaft. Turn the crankshaft clockwise approximately two full turns until bolt (4) can be installed. Install the bolt.c) Install tachometer drive adapter shaft