101401-0370 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014010370 8941310090

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-0370 1014010370

ISUZU 8941310090 8941310090

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Cross reference number

ZEXEL 101401-0370 1014010370

ISUZU 8941310090 8941310090

Zexel num

Bosch num

Firm num

Name

101401-0370
101401-0372

8941310090 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1 *

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 131424-4920

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.6 3.55 3.65

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 -

Rack position 11.4

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 70.5 69 72

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.4)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 70.5 69.5 71.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position 11+-0.5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 70.7 67.5 73.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position 11.3+-0. 5

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 76 72.8 79.2

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position 11.15+-0 .5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 53.5 50.3 56.7

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R2(11.5)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 55 51 59

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position 14.5+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 95 95 103

Fixing the rack *

Timer adjustment

Pump speed r/min 1350+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL
----------
T1=47 RAL=(14.5)mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=5.5deg+-5deg b=41deg+-3deg

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=13deg
----------
a=(100deg)

Information:

Image1.4.1
5. Remove two 135-8573 Bolts from the 268-0555 Hood Group, and remove the 244-8226 Support Assembly.
Image1.5.1
6. Rework the 244-8226 Support Assembly. Refer to the attached images.
Image1.6.1
7. Remove four 135-8573 Bolts from the 268-0555 Hood Group. Remove the 262-2340 Sheet Assembly.
Image1.7.1
8. Rework the 262-2340 Sheet Assembly. Refer to the attached images.
Image1.8.1
10. Attach the 324-4078 Support Assembly to the 262-2340 Sheet Assembly. Use two 135-8573 Bolts and tighten the bolts to a torque of 60+/-10 Nm.
Image1.9.1
11. To attach the 262-2340 Sheet Assembly to the 268-0555 Hood Group, use the four 135-8573 Bolts from Step-7. Tighten the bolts to a torque of 100+/-20 Nm.
12. To attach the 244-8226 Support Assembly to the 268-0555 Hood Group, use the two 135-8573 Bolts from Step-5. Tighten the bolts to a torque of 100+/-20 Nm.
13. To attach the 196-8236 Filter Assembly to the 244-8226 Support Assembly, use the two 8T-4182 Bolts and two 8T-4121 Washers. Tighten the bolts to a torque of 32+/-3 Nm.
Image1.12.1
14. Remove the present fuel hose which connected between the outlet of the fuel priming pump and the inlet of present filter assembly.
Image1.13.1
15. Install the 099-4437 Gasket to both connectors on the 305-4888 Hose. Connect the 305-4888 Hose to the inlet of the new filter assembly using the 094-9726 Bolt and two 095-2040 Washers. Tighten the bolt to a torque of 34+/-4 Nm. Connect the other end of the 305-4888 Hose to the outlet of the fuel priming pump using the bolt and the washer of the priming pump. Tighten the bolt to a torque of 34+/-4 Nm.
16. Install the 7I-7439 Guard( Length is 700mm) to the 305-4888 Hose.
17. Install the 099-4437 Gasket to both connectors on the 305-4887 Hose. Connect the 305-4887 Hose to the outlet of the new filter assembly and inlet of the present filter assembly. Use the 094-9726 Bolt and two 095-2040 Washers in order to connect the hose to the filter assemblies. Tighten the bolts to a torque of 34+/-4 Nm.
18. Install the 7I-7439 Guard (Length is 760mm) to the 305-4887 Hose.
19. Tighten the 094-9725 Plug with the 095-2040 Washer on top of filter base of current fuel filter and additional fuel filter. Tighten the plug to a torque of 8.8+/-1 Nm.
Image1.18.1
20. Use the 294-1833 Clamp, 7X-2533 Bolt, and the 9X-8256 Washer in order to clamp the fuel hose. Tighten the bolt to a torque of 10+/-1 Nm.
Image1.19.1
21. Use two 294-1831 Clamps, 7X-2535 Bolt, two 9X-8256 Washers, and the 5C-2890 Nut in order to clamp the fuel hose. Tighten the bolt to a torque of 10+/-1 Nm.
22. Re-install the two air intake hoses, using the two 8T-4985 Clamps from Step-4. Tighten the clamps to a torque of 4.5+/-0.5 Nm.
Image1.21.1
23. Re-attach the 244-8212 Cover Assembly to the 268-0555 Hood Group. Use the two 135-8573 Bolts, two 135-8575 Bolts, and two 170-3016 Spacers from Step-2. Tighten the bolts to a torque of 100+/-20 Nm.