101402-0310 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014020310 5156011973

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-0310 1014020310

ISUZU 5156011973 5156011973

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Service parts 101402-0310 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8250

3. GOVERNOR 105410-4710

4. SUPPLY PUMP 105220-4932

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156635-6921

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder 5-15300-089-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101402-0310 as INJECTION-PUMP ASSEMBLY

106673-3332 as _

Cross reference number

ZEXEL 101402-0310 1014020310

ISUZU 5156011973 5156011973

Zexel num

Bosch num

Firm num

Name

101402-0310

5156011973 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1 * 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 opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.2 3.15 3.25

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 A

Rack position 9.3

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 75.8 74.3 77.3

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 5.7+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 8.2 6.9 9.5

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=12.5deg+-5deg b=33.5deg+-5deg

Stop lever angle

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

----------
a=12deg+-5deg b=46deg+-5deg

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=15deg44min
----------
a=(90deg)

Information:

Illustration 1 g02004767
(1) Ring for Identification (2) 228-7094 O-Ring Seal (3) 345-3399 Injector Sleeve An oversized injector sleeve will be introduced in order to improve the life cycle of the cylinder heads. The new sleeve has an oversized outside diameter, which does not allow the injector sleeve to fit the standard bore. The oversized sleeve will have an added ring that is located around the middle of the insert for identification. Also, the new sleeve will require a larger bottom O-ring. Refer to Illustration 1.
Illustration 2 g02004793
(4) Identification markThe remanufactured cylinder head has an identification mark that is located on the top of the cylinder head. This mark indicates the cylinders that have the oversized inserts.