101401-7392 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014017392 8971449921


 

Information injection-pump assembly

ZEXEL 101401-7392 1014017392
ISUZU 8971449921 8971449921
101401-7392 INJECTION-PUMP ASSEMBLY
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Service parts 101401-7392 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-8490
3. GOVERNOR 105932-2030
4. SUPPLY PUMP 105210-6170
5. AUTOM. ADVANCE MECHANIS 105676-8050
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-6381
11. Nozzle and Holder 8-97144-997-1
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105048-3673
14. NOZZLE 105017-2220
15. NOZZLE SET

Include in #1:

101401-7392 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101401-7392 1014017392
ISUZU 8971449921 8971449921


Zexel num
Bosch num
Firm num
Name
101401-7392 
101401-7393 
 
8971449921  ISUZU
INJECTION-PUMP ASSEMBLY
* 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   134424-3920
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   12.5
Pump speed r/min   930 930 930
Average injection quantity mm3/st.   70 68.4 71.6
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   9.7+-0.5
Pump speed r/min   330 330 330
Average injection quantity mm3/st.   9.5 8.2 10.8
Max. variation between cylinders %   0 -7 7
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.5)
Pump speed r/min   930 930 930
Average injection quantity mm3/st.   70 69 71
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.9
Pump speed r/min   1550 1550 1550
Average injection quantity mm3/st.   91.5 87.5 95.5
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.25
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   47.7 43.7 51.7
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1+0.4
Pump speed r/min   1240 1240 1240
Average injection quantity mm3/st.   82 78 86
Fixing the lever   *
Timer adjustment
Pump speed r/min   -
Advance angle deg.   0 0 0
Remarks
Measure speed (beginning of operation).
 
Timer adjustment_02
Pump speed r/min   1550
Remarks
Measure the actual advance angle.
 
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   6 6 6
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101401-7392
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=M04
----------

Speed control lever angle

Test data 101401-7392
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=36deg+-5deg b=33deg+-3deg

Stop lever angle

Test data 101401-7392
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg

0000001501 FICD

Test data 101401-7392
(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=415r/min Ra=9.5+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm

0000001601 RACK SENSOR

Test data 101401-7392
Rack sensor adjustment 1. Flange type rack sensor (rack sensor adjustment -5*20) (1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures. (2)Mount the rack sensor main body to the pump main body. (3)Fix the pump lever at full. (4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist. (5)Move the pump lever two or three times. (6)Set again to full. (7)Confirm that the amplifier output voltage is Vist. (8)Fix the caution plate to the upper part of the rack sensor. (For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.) (9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=930r/min Ra=R1(12.5)mm Vist=2.86+-0.28V
----------

Timing setting

Test data 101401-7392
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Timing device stamping (4)At the No 1 cylinder's beginning of injection, align with the aligning mark seen through the bracket's check hole and mark the A/T's bevel C1. (5)B.T.D.C.: aa
----------
aa=8.5deg
----------
a=(60deg) b=(85deg)




Information:

General Recommendations and Contamination Control Guidelines for Fuels
Follow all applicable industry standards and all applicable governmental, environmental, and safety guidelines, practices, regulations, and mandates.Note: These general recommendations and guidelines concerning maintenance and care of fuel and fuel storage systems are not intended to be all inclusive. Discuss proper fuel safety and health, handling, and maintenance practices with your fuel supplier. Use of these general recommendations and guidelines does not lessen the engine owners and/or fuel supplier responsibility to follow all industry standard practices for fuel storage and for fuel handling.Note: Where recommendations for draining water and/or sediment and/or debris are stated, dispose of this waste according to all applicable regulations and mandates.Note: Caterpillar filters are designed and built to provide optimal performance and protection of the fuel system components.Clean fuels, as detailed below, are strongly recommended to allow optimal performance and durability of the fuel systems and to reduce power loss, failures, and related down time of engines.Fuels of “ISO 18/16/13” cleanliness levels or cleaner as dispensed into the engine or machine fuel tank should be used. Reduced power, failures and related downtime can result if clean fuels are not used. Fuels of “ISO 18/16/13” are particularly important for new fuel system designs such as Common Rail injection systems and unit injection systems. These new injection system designs utilize higher fuel pressures and are designed with tight clearances between moving parts to meet required stringent emissions regulations. Peak injection pressures in current fuel injection systems may exceed 30,000 psi. Clearances in these systems are less than 5 µm. As a result, particle contaminants as small as 4 µm can cause scoring and scratching of internal pump and injector surfaces and of injector nozzles.Water in the fuel causes cavitation, corrosion of fuel system parts, and provides an environment where microbial growth in the fuel can flourish. Other sources of fuel contamination are soaps, gels, or other compounds that may result from undesirable chemical interactions in the fuels. Gels and other insoluble compounds can also form in biodiesel fuel at low temperatures or if biodiesel is stored for extended periods. An indication of microbial contamination, detrimental fuel additives interactions, or cold temperature gel is very rapid filter plugging of bulk fuel filters or machine fuel filters.To reduce downtime due to contamination, follow these fuel maintenance guidelines in addition to the recommendations given in the "Contamination Control" Chapter in this Special Publication:
Use high-quality fuels per recommended and required specifications (refer to the “Fuel” chapter in this Special Publication).
Do not add new engine oil, waste engine oil or any oil product to the fuel unless the engine is designed and certified to burn diesel engine oil (for example Caterpillar ORS designed for large engines). Engine oils may raise the sulfur level of the fuel and may cause fouling of the fuel system and loss of performance. Engine oils in fuels can also reduce the maintenance intervals of aftertreatment devices in Tier 4 machines.
Use recommended Cat filtration products, including Cat Advanced Efficiency Fuel

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Group cross 101401-7392 ZEXEL

 
 
INJECTION-PUMP ASSEMBLY

Isuzu 

 
8971449920 
INJECTION-PUMP ASSEMBLY
4HJ1
101401-7392  

101401-7393 
 
8971449921 
INJECTION-PUMP ASSEMBLY
 
8971449922 
INJECTION-PUMP ASSEMBLY
4HJ1
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY

Isuzu 

9 400 613 758 
8971449923 
INJECTION-PUMP ASSEMBLY
4HJ1
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