101401-7350 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014017350 8971417480

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-7350 1014017350

ISUZU 8971417480 8971417480

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Cross reference number

ZEXEL 101401-7350 1014017350

ISUZU 8971417480 8971417480

Zexel num

Bosch num

Firm num

Name

101401-7350
101401-7351

8971417480 ISUZU

INJECTION-PUMP ASSEMBLY
4HF1 * 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 12.1

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 60 58.4 61.6

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. 15.5 14.2 16.8

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(12.1)

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 60 59 61

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.05

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 70 66 74

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.45

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 44 40 48

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=L31
----------

Speed control lever angle

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

----------
a=41deg+-5deg b=35.5deg+-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=400r/min Ra=9.5+-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:

P-226: Fuel Pressure Sensor Test
The 3176 System monitors fuel pressure with a sensor located at the top of the fuel filter housing. The Fuel Pressure Sensor is supplied with 5.0 volts DC through the ECM Connector (J4/P4, Pin 10). The sensor return line goes through the ECM Connector (J4/P4, Pin 35). Both lines are also common with the Coolant Temperature Sensor. The Fuel Pressure Signal goes to the ECM Connector (J4/P4, Pin 39).Fuel pressure is regulated to a maximum of approximately 550 kPa (80 psi). Step 1. Inspect Connectors And WiringInspect the Fuel Pressure Sensor Connector (J16/P16) and the ECM Connector (J4/P4) and wiring between being sure to: * Check Connector lock rings.* Perform 10 pound pull test on each pin or wire.* Inspect wiring for damage or abrasion.* Inspect connectors for damage or corrosion. Refer to P-201: Inspecting Electrical Connectors for details. Repair any damage, then continue with the next step. Step 2. Check Actual Pressure With GaugeA. Install the 8T0846 Pressure Gauge (0 to 145 psi)(part of 1U5470 Pressure Group) on a "T" fitting with the Fuel Pressure Sensor.B. Start the engine and monitor the fuel pressure at low idle.C. Operate the engine at high idle and check the fuel pressure. Fuel pressure at low idle should be greater than 300 kPa (43.5 psi), and at high idle should be 550 85 kPa (80 12 psi) and remain steady. OK: Fuel pressure is within normal limits. Continue to next step. NOT OK: Fuel pressure is outside normal limits, is erratic or leakage is present. The problem is NOT in the 3176 Electronic Control System. Refer to 3176 Vehicular Diesel Engine, Form No. SENR4964, for Systems Operation, Testing & Adjusting, for help in identifying and repairing the cause of the problem. STOP Step 3. Compare Gauge Reading With ECAP/DDTA. With key OFF, install ECAP/DDT on the 3176 System.B. Start the engine and run at low idle. Compare the gauge reading with the display on the ECAP or DDT and record.C. Operate the engine at high idle. Compare the gauge reading with the display on the ECAP or DDT and record. The ECAP/DDT display should be steady and within 40 kPa (6 psi) of the gauge readings. OK: The Fuel Pressure Sensor is operating correctly. STOP. NOT OK: The ECM is not reading fuel pressure correctly. Continue to next step. Step 4. Check Supply Voltage To SensorA. With key OFF, install the 3-Pin Breakout "T" on the Fuel Pressure Wiring Connector (J16) ONLY. Do not connect to the Fuel Pressure Sensor Connector (P16) at this time.B. Turn key ON (engine off).C. Use the multimeter to measure the voltage between + V, Pin A (J16) and Return, Pin B on the 3-Pin Breakout "T". The voltage should be 5.0 0.5 volts DC. OK: The Fuel Pressure Sensor is receiving the correct voltage. Proceed to Step 7. NOT OK: Supply voltage is not reaching the sensor. Continue to next step. Step 5. Check Supply