101402-8360 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014028360 8981178850

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-8360 1014028360

ISUZU 8981178850 8981178850

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Cross reference number

ZEXEL 101402-8360 1014028360

ISUZU 8981178850 8981178850

Zexel num

Bosch num

Firm num

Name

101402-8360

8981178850 ISUZU

INJECTION-PUMP ASSEMBLY
4JG1TPD-0

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 131424-0820

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 3.5 3.45 3.55

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 7.9

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 46.8 45.8 47.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.2+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 11.5 9.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position 9.2++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 105 115

Fixing the lever *

Rack limit *

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)RACK LIMIT (4)Main spring setting (5)Idle sub spring setting: L1. (6)Set at delivery
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K=8 L1=6.2mm+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)When pump speed set at bb (3)When speed is set at cc. (4)Stopper bolt setting
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aa=920r/min bb=900r/min cc=750r/min
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a=3deg+-5deg b=5deg+-5deg c=(1deg) d=15deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

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a=1.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'W' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=5deg
----------
a=(210deg)

Information:

START BY:a. remove fuel injection linesb. disassemble governor**Only disassemble the governor enough so that tooling (D) of Install Fuel Injection Pump can be installed. 1. Remove the plug, and move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to remove the fuel injection pumps.
To prevent possible personal injury carefully follow the steps below.
2. Put tooling (B) except for the 8S4613 Wrench in position on the fuel pump housing as shown. Lower the handle to center the adjusting screw with the fuel line seat. With the handle down in the locked position, the adjusting screw must just be in contact with fuel line seat (1). If force is needed to lower the handle or there is a gap, remove the tooling, and make an adjustment to the screw.3. Loosen bushing (2) 1/4 of a turn.4. Put tooling (B) in position on the pump housing with the handle down in the locked position as shown.5. Remove bushing (2) from the pump housing.6. Carefully and slowly lift the handle to release the spring force. Remove the tooling. 7. Install tool (C) on fuel pump (4) as shown.8. Remove seal (3) and fuel pump (4) from the fuel pump housing. 9. Remove spacers (5) from the pump housing. There must be a pump installed on either side of the pump to be removed to install tooling (B). If there is no pump, take a pump already removed, and remove the spring so there will be no spring force, and install it in the pump housing. See Install Fuel Pump. Spacers (5) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and cannot be mixed.Install Fuel Injection Pumps
1. Install spacers (2) in the fuel pump housing.2. Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Install a fuel pump without its spring so that tool (C) can be installed. See Step 5 for correct fuel pump installation. 4. Install tool (B) on the bonnet of the fuel pump as shown.5. Install the fuel pump in the pump housing with the saw cut (slot) (5) in the gear in alignment with small pin (1) in the lifter assembly and groove (4) in the barrel in alignment with large pin (3) in the pump housing. 6. Install the seal and bushing (6) on the fuel pump.7. Put tooling (C) in position on the fuel pump housing as shown.8. Lower the handle slowly and carefully. If the fuel pump is not installed correctly, the handle will not go all the way down. Do not try to use force on it. Remove and install the tooling and the fuel pump again.9. Make sure the seal is in its correct position, and start to tighten bushing