Information injection-pump assembly
ZEXEL
101492-0880
1014920880
ISUZU
8971912790
8971912790
Rating:
Service parts 101492-0880 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97134-524-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101492-0880
1014920880
ISUZU
8971912790
8971912790
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
Rack position
Point A R=A
Point A R=A
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
7.4
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
62.5
61.5
63.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.3+-0.5
Pump speed
r/min
540
540
540
Average injection quantity
mm3/st.
8.5
6.5
10.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
14++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
70
70
102
Fixing the lever
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Set idle sub-spring
(4)Main spring setting
----------
K=15
----------
----------
K=15
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=(18deg)+-5deg b=(21deg)+-5deg c=35deg+-3deg
----------
----------
a=(18deg)+-5deg b=(21deg)+-5deg c=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=0deg+-5deg b=53deg+-5deg
----------
----------
a=0deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'V' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(210deg)
----------
aa=14deg
----------
a=(210deg)
Information:
Start By:a. remove automatic timing advanceb. remove oil panc. remove water pumpd. remove crankshaft front seal and wear sleeve 1. Disconnect clip (1) for the wiring harness.2. Remove connector (2) from the clip. 3. Fasten Tooling (A) and a hoist to the timing gear cover. The weight of the timing gear cover is 18 kg (40 lb).4. Use Tooling (B) to remove studs (3).5. Move fuel overflow tube (4) out of the way.6. Remove cover (5) and the gasket.7. Disconnect all wiring harness clips from the timing gear housing, and move the wiring harness out of the way.8. Remove the bolts that hold the timing gear cover to the cylinder block, and remove the timing gear cover.9. Remove the gasket for the timing gear cover.10. Thoroughly clean the gasket surface of the cylinder block and the timing gear cover. Be careful not to scratch or mar the gasket surface of the aluminum timing gear cover.Install Timing Gear Cover
1. Install new O-ring seal (1) on the fuel injection pump housing. Put clean engine oil on the O-ring seal.2. Put new gasket (2) in position on the cylinder block. Engage the gasket with the two dowels. Use clean 2S-3230 Bearing Lubricant to hold the gasket in place on the cylinder block. 3. Put the timing gear cover in position on the dowels. Install the bolts that hold the timing gear cover to the cylinder block.4. Install cover (6), and a new gasket.5. Connect the wiring harness clips to the timing gear housing.6. Connect the clip that holds fuel overflow tube (5).7. Use Tooling (B) to install studs (3).8. Remove Tooling (A).9. Put 5P-3413 Pipe Sealant with "Teflon" on the threads of stud (4). Use Tool (B) to install stud (4) to a height of 28.96 mm (1.140 in).10. Install the clip that holds the wiring harness.11. Install the connector in the clip.12. Trim gasket (2) even with the oil pan surface of the cylinder block and timing gear cover.End By:a. install crankshaft front seal and wear sleeveb. install water pumpc. install oil pand. install automatic timing advance
1. Install new O-ring seal (1) on the fuel injection pump housing. Put clean engine oil on the O-ring seal.2. Put new gasket (2) in position on the cylinder block. Engage the gasket with the two dowels. Use clean 2S-3230 Bearing Lubricant to hold the gasket in place on the cylinder block. 3. Put the timing gear cover in position on the dowels. Install the bolts that hold the timing gear cover to the cylinder block.4. Install cover (6), and a new gasket.5. Connect the wiring harness clips to the timing gear housing.6. Connect the clip that holds fuel overflow tube (5).7. Use Tooling (B) to install studs (3).8. Remove Tooling (A).9. Put 5P-3413 Pipe Sealant with "Teflon" on the threads of stud (4). Use Tool (B) to install stud (4) to a height of 28.96 mm (1.140 in).10. Install the clip that holds the wiring harness.11. Install the connector in the clip.12. Trim gasket (2) even with the oil pan surface of the cylinder block and timing gear cover.End By:a. install crankshaft front seal and wear sleeveb. install water pumpc. install oil pand. install automatic timing advance