101685-0190 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016850190 9812009211

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101685-0190 1016850190

ISUZU 9812009211 9812009211

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Service parts 101685-0190 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101068-3610

3. GOVERNOR 105542-6300

4. SUPPLY PUMP 105210-4251

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-2010

11. Nozzle and Holder 9-15300-184-2

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105031-2600

14. NOZZLE

105000-1130

15. NOZZLE SET

Include in #1:

101685-0190 as INJECTION-PUMP ASSEMBLY

Include in #2:

104745-3290 as _

Cross reference number

ZEXEL 101685-0190 1016850190

ISUZU 9812009211 9812009211

Zexel num

Bosch num

Firm num

Name

101685-0190

9812009211 ISUZU

INJECTION-PUMP ASSEMBLY
DA640 * K

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 1-4-2-6- 3-5

Pre-stroke mm 2.2 2.15 2.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 13.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 65 63.5 66.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 13

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 65.3 63.1 67.5

Max. variation between cylinders % 0 -3 3

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 11.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 41 39 43

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position 10+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11 8.7 13.3

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) P:Negative pressure (1)Pneumatic governor (2)Mechanical governor (3)Acting negative pressure: P1
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Information:

10. Remove pin (18), spring and plunger from control lever (14). 11. Remove bearings (19) and two seals (20) from governor housing (13). 12. Remove seat (21), spring washer (22), flat washer (24), spring washer (23) and spring (25). 13. Remove washer (27) from governor bolt (26).14. Remove ring (28) from seat (29). 15. Remove dowel (30) from seat (29). Remove seat (29) and governor bolt (26) as a unit. Remove bolt (26) from seat (29). 16. Remove washer (31), spring (32), washer (33) and sleeve (34) from the servo piston valve. 17. Remove ring (38), large race (37), bearing (35) and small race (36) from sleeve (34). 18. Remove lock (40) from flyweight assembly (39). Remove flyweight assembly (40). 19. Bend the locks from bolts (41) and remove bolts (41).20. Remove bracket (42) and the servo piston assembly as a unit. 21. Remove piston (44) from pin (43). Remove pin (43) from bracket (42). 22. Remove sleeve (45) and valve (46) from piston (44). Remove O-ring seal (47) from sleeve (45). 23. Remove shaft (48) from bracket (42) with a hammer and punch.24. Remove lever (49) from bracket (42). 25. Hit (tap) lightly on cylinder (50) to remove it from the governor plate. 26. Remove O-ring seals (51) from cylinder (50). 27. Remove spiral ring (53), and then remove dowel (52) behind the spiral ring. 28. Remove drive assembly (54) and stop (55) from drive gear (56). 29. Turn the governor plate over and remove snap ring (57) from drive gear (56) with tool (B).30. Remove drive gear (56) from the governor plate. 31. If a replacement is needed, remove dowels (59), (60) and (61).32. Remove bearing (58) from the governor plate with tooling (A).Assemble Governor
1. If a replacement of the dowels in the governor plate is necessary, see illustration for correct installation dimensions. 2. Install bearing (1) for drive gear (2) in governor plate (3) with tooling (A) until it is .020 .010 in. (0.51 0.25 mm) below the top surface of the governor plate. 3. Put a small amount of clean engine oil on the inside diameter of bearing (1). Install drive gear (2) in governor plate (3). 4. Turn governor plate (3) over and install snap ring (4) that holds drive gear (2) in place. 5. Install O-ring seals (6) on cylinder (5). 6. Put a small amount of clean engine oil on the O-ring seals on cylinder (5). Install cylinder (5) in the governor plate with the notch in the cylinder in alignment with the bolt hole in the governor plate as shown.7. Install the O-ring seal on sleeve (9).8. Put a small amount of clean engine oil on piston (7), sleeve (9) and valve (8). Install sleeve (9) on piston (7) and valve (8) in piston (7) as shown.9. Install the servo piston assembly in cylinder (5). The valve (8), sleeve (9) and piston (7) are parts of the servo piston assembly. 10. Put lever (11) in position in bracket