Information injection-pump assembly
ZEXEL
101492-0680
1014920680
ISUZU
8970815730
8970815730
Rating:
Cross reference number
ZEXEL
101492-0680
1014920680
ISUZU
8970815730
8970815730
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
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)
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
3.3
3.25
3.35
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
10.3
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
52
51
53
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.1+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
11.5
9.5
13.5
Max. variation between cylinders
%
0
-15
15
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.
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)Set idle sub-spring
(4)Main spring setting
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=9deg+-5deg b=20deg+-5deg c=35deg+-3deg
----------
----------
a=9deg+-5deg b=20deg+-5deg c=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=2.5deg+-5deg b=53deg+-5deg
----------
----------
a=2.5deg+-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=17deg
----------
a=(210deg)
----------
aa=17deg
----------
a=(210deg)
Information:
Start By:a. remove governor 1. Remove the bolts and the plate from the side of the fuel injection pump housing.2. Install Tool (A) in the fuel injection pump housing. Move the rack until Tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to remove the fuel injection pumps.3. Use Tool (B) to remove bushing (1) from the fuel injection pump housing.4. Remove the O-ring seal from the fuel injection pump housing. Spacers (2) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and can not be mixed.5. Install Tool (C) on the bonnet. Remove the fuel injection pump. 6. Remove spacer (2) from the fuel injection pump housing.7. Do Steps 3 through 6 to remove the other fuel injection pumps.Install Fuel Injection Pumps
1. Install spacer (1) in the fuel injection pump housing. 2. Install Tool (A) in the fuel injection pump housing. Move the rack until Tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Turn the camshaft until the lobe of the camshaft is down for the pump to be installed.4. Install Tool (B) on the bonnet of the fuel injection pump.5. Install the fuel injection pump in the pump housing with saw cut (slot) (3) in the gear in alignment with the small pin (2) and groove (4) in the barrel in alignment with dowel (5) in the pump housing. 6. Put clean oil on O-ring seal (6). Install it in the fuel injection pump housing.7. Install the bushing by hand until it is even with the top of the housing. If the bushing can not be installed this far by hand, remove it. Remove the fuel injection pump, and put the pump in alignment again, and install the bushing again. 8. Install Tool (C) on the bushing and tighten the bushing to a torque of 190 14 N m (140 10 lb ft). 9. Install Tool (D) to measure total rack travel. Correct rack travel is 15.7 mm (.618 in). A smaller measurement is an indication of incorrect fuel injection pump installation.10. Do Steps 1 through 9 again for installation of the other fuel pumps.11. Install the cover and gasket on the fuel injection pump housing.End By:a. install governorDisassemble Fuel Injection Pumps
Start By:a. remove fuel injection pumps
Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
1. Pull plunger (1) and
1. Install spacer (1) in the fuel injection pump housing. 2. Install Tool (A) in the fuel injection pump housing. Move the rack until Tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Turn the camshaft until the lobe of the camshaft is down for the pump to be installed.4. Install Tool (B) on the bonnet of the fuel injection pump.5. Install the fuel injection pump in the pump housing with saw cut (slot) (3) in the gear in alignment with the small pin (2) and groove (4) in the barrel in alignment with dowel (5) in the pump housing. 6. Put clean oil on O-ring seal (6). Install it in the fuel injection pump housing.7. Install the bushing by hand until it is even with the top of the housing. If the bushing can not be installed this far by hand, remove it. Remove the fuel injection pump, and put the pump in alignment again, and install the bushing again. 8. Install Tool (C) on the bushing and tighten the bushing to a torque of 190 14 N m (140 10 lb ft). 9. Install Tool (D) to measure total rack travel. Correct rack travel is 15.7 mm (.618 in). A smaller measurement is an indication of incorrect fuel injection pump installation.10. Do Steps 1 through 9 again for installation of the other fuel pumps.11. Install the cover and gasket on the fuel injection pump housing.End By:a. install governorDisassemble Fuel Injection Pumps
Start By:a. remove fuel injection pumps
Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
1. Pull plunger (1) and