101402-0430 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014020430 5156013462

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-0430 1014020430

ISUZU 5156013462 5156013462

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Buy INJECTION-PUMP ASSEMBLY 101402-0430 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-0430 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8180

3. GOVERNOR 105410-5860

4. SUPPLY PUMP 105220-4772

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156635-6621

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:

101402-0430 as INJECTION-PUMP ASSEMBLY

106679-3010 as _

Cross reference number

ZEXEL 101402-0430 1014020430

ISUZU 5156013462 5156013462

Zexel num

Bosch num

Firm num

Name

101402-0430

5156013462 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1 * K 14BC PE4A,5A, PE

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

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 3.6 3.55 3.65

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 9.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 54.1 52.1 56.1

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 58.5 57 60

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10.2 8.8 11.6

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=6
----------

Speed control lever angle

I:Idle (1)Pump speed = aa (2)Stopper bolt setting (3)Speed = bb (at shipping)
----------
aa=950r/min bb=1100r/min
----------
a=1deg+-5deg b=4deg+-5deg c=21deg+-5deg

Stop lever angle

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

----------
a=19deg+-5deg b=53deg+-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=18deg
----------
a=(90deg)

Information:

Remove the single tie bolt (6) that is located in the top left corner of the pump by using Tooling (B). Refer to Illustration 7. Only remove the single tie bolt (6). Removing more bolts will result in damage to the pump.
Illustration 2 g01132938
(1) HEUI pump (2) Fuel transfer pump (4) Drive gear (5) 227-5904 O-Ring Seal (6) Tie Bolt (7) Bolts for the fuel transfer pump (8) Tie Bolts (9) Location for service bolt (12) 185-3241 O-Ring Seal
Replace tie bolt (6) with the temporary service bolt (9) that is provided in the service kit.Note: The service bolt that is provided in the kit has an undersized bolt head. The service bolt prevents the body of the HEUI pump from separating during service. Do not remove the service bolt until the fuel transfer pump has been completely reinstalled.
Tighten the service bolt (9) to 10 N m (7.4 lb ft) by using Tooling (C) .Note: Do not place an excessive torque on the service bolt. The aluminum housing of the pump could be damaged.
After installing the service bolt (9) in the top left location, remove the three bolts (7) that fasten the fuel transfer pump to the HEUI pump by using Tooling (A) .
Proceed by removing the remaining three tie bolts (8) by using Tooling (B) .
Separate the fuel transfer pump from the HEUI pump. Refer to Illustration 3.
Illustration 3 g01132944
(1) HEUI pump (2) Fuel transfer pump (9) Service bolt (10) Seals (11) SealInstalling the Fuel Transfer Pump onto the HEUI Pump
Install the two new 239-2402 Seals (10) on the back face of the HEUI pump (1). Refer to Illustration 4.
Illustration 4 g01077898
(1) HEUI pump (10) 239-2402 Seals
Install a new 179-8128 Seal (11) on the fuel transfer pump (2). Refer to Illustration 5. Use 1U-6396 O-Ring Assembly Compound in order to hold the seal in place during assembly. Ensure that the seal is completely seated.
Illustration 5 g01132957
(2) Fuel transfer pump (11) 179-8128 Seal
Do not remove the service bolt. Position the fuel transfer pump on the HEUI pump. Be sure to properly align the drive tang on the fuel transfer pump with the drive slot on the HEUI pump.Note: Align the drive tang of the fuel transfer pump so that the flat end is vertical. Refer to Illustration 5. Align the drive slot in the HEUI pump to a similar vertical orientation by using a flat head screwdriver. Refer to Illustration 6.
Illustration 6 g01132969
Note: Once the fuel transfer pump has been placed onto the HEUI pump, ensure that the face of the fuel transfer pump is flush with the face of the HEUI pump. If the pump faces are not flush, verify the alignment of the drive tang.
Install the three mounting bolts (7) for the fuel transfer pump (2). Tighten