101492-0790 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014920790 8971385920

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101492-0790 1014920790

ISUZU 8971385920 8971385920

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Buy INJECTION-PUMP ASSEMBLY 101492-0790 zexel genuine, new aftermarket engine parts with delivery

Service parts 101492-0790 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8670

3. GOVERNOR 105419-0220

4. SUPPLY PUMP 105220-4772

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-2720

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4372

11. Nozzle and Holder 5-15300-103-2

12. Open Pre:MPa(Kqf/cm2) 14.7{150}

13. NOZZLE-HOLDER 105030-3391

14. NOZZLE

105015-3930

15. NOZZLE SET

Include in #1:

101492-0790 as INJECTION-PUMP ASSEMBLY

106691-4120 as _

Cross reference number

ZEXEL 101492-0790 1014920790

ISUZU 8971385920 8971385920

Zexel num

Bosch num

Firm num

Name

101492-0790

8971385920 ISUZU

INJECTION-PUMP ASSEMBLY
4BC2 * K

Calibration Data:

Adjustment conditions

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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 11

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 44.6 43.6 45.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 12.2

Pump speed r/min 725 725 725

Average injection quantity mm3/st. 70.4 68.9 71.9

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point -

Rack position 10.2+-0. 5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 12 10.5 13.5

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
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)RACK CAP: R1 (4)Main spring setting (5)Set idle sub-spring
----------
K=16 R1=(17.5)mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)Set the pump speed at bb (at delivery) (3)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=16deg+-5deg b=4deg+-5deg c=5deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
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)

Information:

1. Remove tachometer drive (3) from transfer pump cover (4).2. Remove bolts (1). Separate cover (4) and pump body (2). 3. Remove lip-type seal (6) from the cover. Remove plug (5), the seal, spring and plunger (bypass valve) from the cover. 4. Remove nut (10) from shaft (7). Remove gear (9) and key (11).5. Remove shaft (7) and gear (8) as a unit. Remove gear (8) from drive shaft (7) with a press.6. Remove idler gear (12). 7. Remove bushing (14), two lip-type seals and the bottom bearing from pump body (2).8. Remove check valve (13).Assemble Fuel Transfer Pump
1. Install bushing (4) in body (3) with Tooling (B). The bushing must be .80 .50 mm (.031 .020 in) below the (gear) surface of the body.2. Install the check valve in the body with Tooling (A).3. Install lip-type seal (5) with Tooling (C). Install the seal until it is 26.19 .13 mm (1.031 .005 in) from the bottom (drive gear) surface of body (3) and with the lip toward bushing (4) as shown.4. Install lip-type seal (6) with Tooling (D). Install the seal until it is 14.2 0.5 mm (.559 .020 in) from the bottom (drive gear) surface of body (3) and with the lip away from seal (5) as shown.5. Install bearing (7) in body (3) with Tooling (E). The bearing must be even with the bottom (drive gear) surface of the pump body. 6. Heat gear (8) to a maximum temperature of 315° C (600° F). Install gear (8) on shaft (11) until dimension (X) is 49.71 0.25 mm (1.957 .010 in).7. Install the drive shaft and gear in body (3). Install the key, gear (10) and nut (9). Tighten the nut to a torque of 30 7 N m (22 5 lb ft).8. Install idler gear (12) in body (3).9. Install lip-type seal (2) with Tooling (C). Install the seal until it is 22.61 .05 mm (.890 .002 in) from the top surface of cover (1) with the lip toward the inside as shown. 10. Install plunger (14) (bypass valve), spring (15) and seal and plug (13) in pump cover (1). Tighten plug (13) to a torque of 37 4 N m (27 3 lb ft).
Do not let the liquid gasket enter the pump during application or assembly.
11. Put 7M-7260 Liquid Gasket Material on the surface of cover (1). Install cover (1) on pump body (3). The drive shaft must turn freely after the bolts that hold the transfer pump together are tightened.12. Install the tachometer drive on cover (1).End By:a. install fuel transfer pump