101441-0020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014410020 9812007961

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101441-0020 1014410020

ISUZU 9812007961 9812007961

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Service parts 101441-0020 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP

3. GOVERNOR 105542-6340

4. SUPPLY PUMP 105220-1590

5. AUTOM. ADVANCE MECHANIS 105621-0260

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105151-1260

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER 105081-3030

14. NOZZLE

105000-1080

15. NOZZLE SET

Include in #1:

101441-0020 as INJECTION-PUMP ASSEMBLY

Include in #2:

105856-1974 as _

Cross reference number

ZEXEL 101441-0020 1014410020

ISUZU 9812007961 9812007961

Zexel num

Bosch num

Firm num

Name

101441-0020

9812007961 ISUZU

INJECTION-PUMP ASSEMBLY
C240 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle 105000-1080

Bosch type code DN0SD211

Nozzle holder 105081-3030

Opening pressure MPa 11.8

Opening pressure kgf/cm2 120

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 132424-0620

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 1.95 1.9 2

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 11.8

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 43 41.9 44.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.8

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 43.3 41.4 45.2

Max. variation between cylinders % 0 -4.5 4.5

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 12.4

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 41.3 39.7 42.9

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position 8+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8 6.9 9.1

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_05

Adjusting point -

Rack position -

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 43 42 44

Remarks
Smoke setting

Timer adjustment

Pump speed r/min 500+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 800

Advance angle deg. 1 0.5 1.5

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 2 1.2 2.7

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 4.5 3.9 4.9

Timer adjustment_05

Pump speed r/min 1750

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) P:Negative pressure (1)Pneumatic governor (2)Mechanical governor (3)Acting negative pressure: P1 (4)Beginning of idle sub spring operation: L1 (5)Injection quantity Q = Q1 or less
----------
P1=6.37+-0.2kPa(650+-20mmAq) L1=9+0.3mm Q1=3mm3/st
----------

Stop lever angle

S:Stop the pump. (1)Rack position = at least aa
----------
aa=17.5mm
----------
a=(14deg) b=(23deg)

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(130deg)

Information:

Introduction
This Special Instruction contains the necessary procedure in order to install unit injectors for 3114, 3116, and 3126 MUI engines.Removal and Installation Procedure
Note: To avoid damage to the unit injector during removal of the unit injector from the cylinder head, refer to the Service Manual for the removal procedure of the unit injector.Use the latest process for servicing the unit injector sleeves in the cylinder head before you install replacement unit injectors. Refer to the Service Manual and other service news articles in order to find the latest service information, including new tools and procedures.Before a new unit injector or a remanufactured unit injector is installed into an engine, take adequate precautions in order to clean the internal fuel lines and the unit injector sleeve. Also, install a new Caterpillar high efficiency fuel filter.Lubricate the injector rack bar with clean diesel fuel or 1U-8265 Penetrating Oil .
Illustration 1 g02144296
Incorrect testing procedure for the tappet springDo not depress the tappet spring. Refer to Illustration 1. Do not force the injector rack bar in and out since this action may damage the internal parts of the unit injector. A tight rack on a unit injector that is not installed in the engine is not an indication of a faulty unit injector. Forcing the injector rack bar in and out may cause the unit injector to become damaged. Forcing the injector rack bar in and out may possibly void all the warranty.Do not test the unit injectors prior to engine installation. The unit injectors are tested 100% at the factory and Pop Testing may contaminate the unit injector.Before you install the unit injector, apply clean engine oil on the O-ring seals for ease of installation.Install the unit injector according to the procedure in the Service Manual by using 173-1530 Injector Seating Tool . Tighten the unit injector clamp retaining bolt to a torque of 12 3 N m (9 2 lb ft).Verify the following parameters and settings according to the procedures in the Service Manual: unit injector synchronization, fuel setting, fuel timing and valve lash. Adjust the parameters and settings in order to meet specifications only.