101402-7300 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014027300 8971910930

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-7300 1014027300

ISUZU 8971910930 8971910930

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Cross reference number

ZEXEL 101402-7300 1014027300

ISUZU 8971910930 8971910930

Zexel num

Bosch num

Firm num

Name

101402-7300
101402-7301

8971910930 ISUZU

INJECTION-PUMP ASSEMBLY
4BG1 * 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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.4 3.35 3.45

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 8.8

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 83.5 82.4 84.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 8.5 7.1 9.9

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 (2)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Main spring setting
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K=12
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Speed control lever angle

F:Full speed I:Idle S:Stop
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a=18deg+-5deg b=30deg+-5deg c=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=4.5deg+-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=15deg
----------
a=(100deg)

Information:

Remove Brakesaver
start by:a) remove flywheel (BrakeSaver) 1. Disconnect BrakeSaver lubrication oil line (1) from the fitting in the BrakeSaver housing. 2. Disconnect the oil line from fitting (5).3. Remove two short bolts (2) and two longer bolts (4) that hold manifold (3) to the BrakeSaver housing. Remove manifold (3) from the BrakeSaver control valve.4. Remove the O-ring seals from the manifold. The two longer bolts (4) from the manifold can be used as forcing screws to remove the BrakeSaver from the flywheel housing.5. Install a 3/8"-16 NC forged eyebolt in the top of the BrakeSaver housing and fasten a hoist. 6. Install tooling (A) on the BrakeSaver housing and rotor. Tooling (A) holds the BrakeSaver housing and rotor assembly together at removal. This prevents damage to the rotor rings and seals.7. Remove bolts (6) that hold BrakeSaver housing (7) to the flywheel housing.8. Use bolts (4) as forcing screws and tighten the bolts evenly to remove BrakeSaver housing (7) from the flywheel housing. The weight is 190 lb. (86 kg).Install Brakesaver
1. Install tooling (A) on BrakeSaver housing and rotor. Tooling (A) holds the BrakeSaver housing and rotor assembly together at installation. This prevents damage to the rotor rings and seals.2. Install a 3/8"-16 NC forged eyebolt in the top of the BrakeSaver housing and fasten a hoist.3. Install two 5/8"-18 guide pins (3) in the crankshaft as shown. Make sure dowel (2) is in alignment with the dowel hole in the rotor assembly and put BrakeSaver housing (1) in position in the flywheel housing.4. Install the three bolts that hold the BrakeSaver housing to the flywheel housing. Remove tooling (A) and guide pins (3). 5. Connect the oil line to fitting (6).6. Inspect the O-ring seals for damage and make replacements if needed. Install O-ring seals (4) and (5). Put clean oil on the O-ring seals.7. Install manifold (7) into the BrakeSaver control valve and install the four bolts that hold the manifold to the BrakeSaver housing. 8. Connect BrakeSaver lubrication oil line (8) to the fitting in the BrakeSaver housing.end by:a) install flywheel (BrakeSaver)Disassemble Brakesaver
start by:a) remove BrakeSaver1. Remove tooling (A) from the BrakeSaver housing and rotor. Tooling (A) prevents damage to the rotor seals and rings at removal of the BrakeSaver housing. 2. Remove bolts (1) from gear plate (2). Remove the plate. 3. Make identification as to the location of stator (3) with housing (4). Remove bolts (5) and the stator. 4. Turn the stator over and remove spiral ring (6). 5. Turn the stator over again. Remove sleeve assembly (9). Remove O-ring seal (7) and lip type seal (8) from the sleeve. 6. Remove O-ring seal (11) and the six smaller O-ring seals from the oil holes on the housing.7. Remove rotor assembly (12).8. Remove seal ring (10) from both sides of the rotor. 9. Remove carrier (13) and wear sleeve (14) with tooling (B) from both sides of the rotor. 10. Remove spiral ring (15). Turn the housing over and remove sleeve assembly