101401-7060 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014017060 8971223561

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-7060 1014017060

ISUZU 8971223561 8971223561

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Cross reference number

ZEXEL 101401-7060 1014017060

ISUZU 8971223561 8971223561

Zexel num

Bosch num

Firm num

Name

101401-7060
101401-7061

8971223561 ISUZU

INJECTION-PUMP ASSEMBLY
A * 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 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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 4.1 4.05 4.15

Rack position
Point A R=A

Beginning of injection position
Governor 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 12

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 54 52.4 55.6

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 9.8+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 14 12.7 15.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12)

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 54 53 55

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 65 61 69

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 46.5 42.5 50.5

Fixing the lever *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=L48
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)-
----------

----------
a=41deg+-5deg b=(35deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg

0000001501 FICD

(A) applied negative pressure (B) Screw (c) Nut 1. Set the actuator as described below. (1)Confirm that there is clearance between the actuator lever and the speed lever. (2)Loosen the nut (C). (3)Push in the screw (B). (4)Apply P1 from the actuator (A) part. (5)Pull out the screw (B) slowly. (6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra. (7)Torque the nut (C) to T1. (8)Apply P2 several times. (9)Confirm that the actuator functions normally. (10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=440r/min Ra=9.2+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Stamping position on the A/T outer rim (4)Pump bracket check hole position. (5)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1. (6)B.T.D.C.: aa
----------
aa=8deg
----------
a=(60deg) b=(85deg)

Information:

Introduction
The 7C8966, 7C8972, 8N5651, 8N5887, 9N0495, and 9N5864 Fuel Injection Pump Groups (new), or the 0R0766, 0R0902, 0R0903, 0R2374, and 0R2385 Fuel Injection Pump Group [remanufactured - (reconditioning has been done to a used fuel injection pump and governor group to give the same quality as a new pump group)] are service replacements for the fuel injection pump and governor groups used on 3208 engines, according to the adaptability shown in the chart. These service groups have only those gaskets and seals that are needed to install the fuel injection pump and governor on the engine.Reference: Parts Manual, Service Manual, Engine Information Plate, Fuel Setting Information Microfiche, Fuel System and Related Information MicroficheDo not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.Service Group Chart
Removal and Installation
1. Remove the pump and governor from the engine. Refer to the Service Manual.
When a replacement fuel injection pump and governor is installed on an engine (or when replacement parts are put in a fuel injection pump and governor), use the information on the engine information plate and always check engine low idle speed, set point and the fuel setting dimension. These settings and dimensions must be checked and adjustments made by a mechanic that has the necessary training in fuel system maintenance. Before the fuel system checks and adjustment are made, remove the original factory fuel system seal. After all fuel system work has been completed, install your Dealer seal as a replacement seal. Refer to Fuel System and Related Information or Fuel Setting Information for additional specifications.
2. Put the new service pump group in a 2P8315 Bracket Assembly (1) so it will be easier to work on. Remove the shut-off solenoid and the solenoid ground wire from the old fuel system. Remove the fuel line fittings from the old fuel system. Install these parts in the same location on the new fuel system.3. Locate the engine serial number and write it down. Make reference to the Fuel Setting Information or Fuel System and Related Information to find the part number of the governor high idle spring that is needed for the engine. The same part number governor high idle spring given in the Fuel Setting Information, or the Fuel System and Related Information must be installed in the new service pump group. The 9L6508 High Idle Spring is already installed in the service pump and governor groups. The governor high idle spring needs to be changed only if the needed part number is different than 9L6508. If it is necessary to change the high idle spring, refer to the Service Manual. The part number of the low idle spring is 4N5663 and is the same for all fuel systems.4. A 4N0527 Overfueling Spring is installed in the service pump and governor groups. Refer to the Parts Manual to determine which overfueling spring is required. If the overfueling spring must be changed, refer to the Service Manual for the