101401-0772 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014010772 8944551021

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-0772 1014010772

ISUZU 8944551021 8944551021

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Cross reference number

ZEXEL 101401-0772 1014010772

ISUZU 8944551021 8944551021

Zexel num

Bosch num

Firm num

Name

101401-0772
101401-0773

8944551021 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1T *

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 3.4 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 -

Rack position 11.6

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 72.1 70.5 73.7

Max. variation between cylinders % 0 -4 4

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 325 325 325

Average injection quantity mm3/st. 12.1 10.8 13.4

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(11.6)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 72.1 71.1 73.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 82.6 79.4 85.8

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 53.6 49.6 57.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position (R1+0.1)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 76.1 72.9 79.3

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 116 116 124

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1000+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C52
----------

Speed control lever angle

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

----------
a=3.5deg+-5deg b=27deg+-3deg

Stop lever angle

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

----------
a=45deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(11.6)mm Rb=(R1-0.15)mm Pa=79.4+-2.7kPa(596+-20mmHg) Pb=70.1+0.7kPa(526+-5mmHg) Q1=72.1+-1cm3/1000st Q2=69.8+-1.6cm3/1000st

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:

2. Removing Accessories
(1) Removing Fan(a) Reduce the tension applied by the tension pulley by pushing the alternator toward the engine, then remove the water pump drive belt (1).(b) Remove the fan mounting bolts (2), then remove the fan (3).(c) Remove the water pump pulley (4), which was previously retained by the fan mounting bolts (2).(2) Removing Thermostat FittingRemove the water outlet fitting (1), then remove the thermostat (2), thermostat fitting (3), water joint (4), and temperature joint (5) in that sequence. (3) Removing Exhaust and Intake Manifolds(a) Remove the exhaust manifold mounting bolts, then remove the exhaust manifold (1) and the gasket (2).(b) Remove the intake manifold mounting bolts, then remove the intake manifold (3) and the gasket (4). When refitting the manifolds, fit each gasket with the side marked "MANIFOLD" facing the manifold. (4) Removing Water PumpRemove the water pump mounting bolts, then remove the water pump (1). (5) Removing Alternator(a) Disconnect the battery cables.(b) Disconnect the lead from terminal B at the rear of the alternator.(c) Remove the alternator connector.(d) Loosen the alternator brace bolt (1) and support bolt (2), then push the alternator toward the engine and remove the fan belt.(e) Remove the alternator. (6) Removing Starter(a) Disconnect the battery's (-) and (+) terminals in that sequence.(b) Disconnect the start wiring (1).(c) Remove the starter's two mounting bolts (2), then remove the starter (3). (7) Removing Oil Filter(a) The oil filter (2) must be replaced every 100 hours of use.(b) Remove the oil filter using a filter wrench (1). (8) Removing Fuel Filter(a) Remove the fuel pipe (1) that leads from the fuel tank and the fuel pipe (2) that leads to the fuel pump.(b) Remove the fuel filter (3) from the engine. (9) Removing Fuel Pipes(a) Remove the clamps from the four fuel pipes (1), then disconnect the fuel pipes from the engine and from the injection pump.(b) Remove the joints and clips from the fuel hose (2), then disconnect the fuel hose from the injector holders.
To keep dirt out of the fuel system, fit rubber caps over the parts of the injection pump and injector inlet connectors from which the injection pipes are disconnected.
(10) Removing Injection Pump
1 Fuel hose2 Fuel pipe3 Tie rod cover4 Tie rod spring5 Tie rod6 Injection pump7 Adjustment shim8 Control rack pin(a) Remove the tie rod cover (3).
Removing tie rod cover(b) Using long-nosed pliers, remove the tie rod spring (4) from the control rack pin (8) and from the governor lever pin.(c) Remove the tie rod (5).
Removing tie rod(d) Remove the injection pump (6) and the adjustment shim (7).
Removing injection pump(11) Removing Oil PumpRemove the oil pump's four mounting bolts, then remove the oil pump (1). (12) Removing InjectorDisconnect the fuel injection pipe (1) and the fuel hose (2) before removing the injector (3). 3. Refitting Accessories
3.1 General PointsRefit accessories by following the removal procedures in reverse. After refitting accessories, perform the following operations:(1) Pour the specified amount of engine oil into the engine.(2) Pour coolant into the cooling