101685-0780 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016850780 9812009262

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101685-0780 1016850780

ISUZU 9812009262 9812009262

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Buy INJECTION-PUMP ASSEMBLY 101685-0780 zexel genuine, new aftermarket engine parts with delivery

Service parts 101685-0780 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101068-3640

3. GOVERNOR 105412-0300

4. SUPPLY PUMP 105210-4251

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3160

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:

101685-0780 as INJECTION-PUMP ASSEMBLY

Include in #2:

104745-3350 as _

104745-3351

104745-3352

Cross reference number

ZEXEL 101685-0780 1016850780

ISUZU 9812009262 9812009262

Zexel num

Bosch num

Firm num

Name

101685-0780

9812009262 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 lever *

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 9.8

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) (1)Target notch: K (2)At rack cap installation: R1
----------
K=8 R1=(17.5)mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=17deg+-5deg b=33.5deg+-5deg c=32deg+-3deg

Information:

2. Remove bolts (1).3. Remove the water hose from the bottom of the water pump.4. Loosen the water hose clamps from water pipe (2).5. Remove two bolts (3) and remove the water pump and elbow as a unit.Install Water Pump
1. Inspect all O-rings, gaskets and hoses and install new parts if needed.2. Put the water pump and elbow in position and install the bolts.3. Install the water hose and tighten all water hose clamps.4. Fill the cooling system to the correct level.Disassemble Water Pump
start by:a) remove water pump1. Remove cover (3) and gasket from water pump (1).2. Remove elbow (2) and gasket from water pump (1). 3. Loosen bolt (5) .25 in. (6.35 mm). Hit (tap) the bolt with a soft hammer to remove impeller (4) from the shaft. 4. Remove spring and seal assembly (7) from shaft (6). 5. Turn the water pump over and remove bolt (8) and lockwasher.6. Remove O-ring seal (9) from the housing. 7. Use tooling (A) to remove gear (11) and bearing (10) from the water pump.8. Remove bearing (10) from gear (11). 9. Remove snap ring (12) with tool (B). 10. Remove bearing (14) and shaft (13) as a unit.11. Use tool (C) and a press to remove bearing (14) from the shaft. 12. Remove the ceramic ring and seal (15) from the housing. 13. Remove the lip type seal (16) from the housing with tooling (D).Assemble Water Pump
The seal must be installed with the lip toward the bearings.1. Install the lip type seal in housing (1) with tooling (A) to the bottom of the seal counterbore. Put a thin layer of engine oil on the lip of the seal. 2. Use a press to install shaft (2) in bearing (3). 3. Install the shaft and bearing (3) in housing (1). 4. Install snap ring (4) in the housing with tool (B). 5. Install bearing (5) on gear (6).
When gear (6) is installed, make sure the pins on the gear engage the holes in the shaft.
6. Put gear (6) and bearing in position on the shaft and install washer and bolt. 7. Install O-ring seal (7) on the housing.
Clean water only is permitted for use as a lubricant to make assembly easier. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
8. Put the ceramic ring (8) in position in the rubber seal. Use hand pressure and tool (which is with the replacement ring) to install the ceramic ring and rubber seal. 9. Remove the spring from the seal assembly (9). Use hand pressure and the tool (which is with the replacement ring) to install the seal assembly. Push seal assembly on the shaft until seal faces make light contact. 10. Install spring (10) on the seal assembly. 11. Put impeller (11) in position on the shaft. 12. Install washer and bolt (12). Tighten the bolt to