101401-0621 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014010621 8941778750

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-0621 1014010621

ISUZU 8941778750 8941778750

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Cross reference number

ZEXEL 101401-0621 1014010621

ISUZU 8941778750 8941778750

Zexel num

Bosch num

Firm num

Name

101401-0621
101401-0622

8941778750 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1T *

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 -

Rack position 11.8

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 72.6 71 74.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 11.4 10.1 12.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.8)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 72.6 71.6 73.6

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.05

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 80.1 76.9 83.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.05

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 56 52.8 59.2

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 116.5 116.5 124.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1150+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1500

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B39
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=2.5deg+-5deg b=34deg+-3deg

Stop lever angle

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

----------
a=45deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(11.8)mm Rb=(R1-0.3)mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=72.6+-1cm3/1000st Q2=67+-1.5cm3/1000st

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=6deg
----------
a=(100deg)

Information:

Thermostat Removal
Stop engine.Disconnect negative (-) battery cable at battery.
Do not drain engine coolant until the coolant temperature is below operating temperature. Then loosen drain cock slowly to relieve any excess pressure.
Remove coolant from cooling system.
Fig. 1-Thermostat CoverDisconnect upper radiator hose from thermostat cover (Fig. 1).Remove thermostat cover.Remove gasket.
Fig. 2-ThermostatLift thermostat (Fig. 2) out of thermostat housing.Repair
Fig. 3-Thermostat OpenIf engine is running too hot or too cold inspect thermostat for defects. Test in hot water for proper opening and closing.Installation
Some thermostats are marked "TO RAD", "THIS SIDE TOWARD RADIATOR", or "TOWARD RADIATOR" to indicate the top side. Put thermostat in housing so that top side is toward thermostat cover.
Fig. 4-Top SideIf thermostat is not marked, find the top side (Fig. 4). Put thermostat in housing so that top side is toward thermostat cover.
Fig. 5-Cap ScrewUsing a new gasket, install thermostat cover. Put cap screws (Fig. 5) through thermostat cover into thermostat housing. Tighten cap screws to 35 lb-ft (47 N m) (5 kg-m).Connect upper radiator hose to thermostat cover.Fill cooling system to proper level with proper coolant.Connect negative (-) battery cable to battery negative (-) terminal.Start engine.Check for leaks at hose connection and around gasket area.