101401-0640 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014010640 8944077400

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-0640 1014010640

ISUZU 8944077400 8944077400

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Service parts 101401-0640 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8340

3. GOVERNOR 105931-0512

4. SUPPLY PUMP 105220-4882

5. AUTOM. ADVANCE MECHANIS 105622-0730

6. COUPLING PLATE

7. COUPLING PLATE

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:

101401-0640 as INJECTION-PUMP ASSEMBLY

107691-3062 as _

Cross reference number

ZEXEL 101401-0640 1014010640

ISUZU 8944077400 8944077400

Zexel num

Bosch num

Firm num

Name

101401-0640
101401-0641

8944077400 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1 *

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 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)
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 -

Rack position 11.2

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 66.7 65.1 68.3

Max. variation between cylinders % 0 -4 4

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 290 290 290

Average injection quantity mm3/st. 8 6.7 9.3

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(11.2)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 66.7 65.7 67.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.4

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 63.3 60.1 66.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.1

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 70.7 67.5 73.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.25

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 49.6 46.4 52.8

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 49 45 53

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position 14.5+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 95 95 103

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1250

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1350

Advance angle deg. 1.1

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 1.6

Timer adjustment_04

Pump speed r/min 1600

Advance angle deg. 5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL (3)Torque cam set point
----------
T1=47 RAL=(14.5)mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=30deg+-5deg b=41deg+-3deg

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=13deg
----------
a=(100deg)

Information:

Fan Belt
Removal
Fig. 1-Cap Screw and BoltLoosen cap screw and alternator mounting bolt (Fig. 1). Move alternator so fan belt can be moved off pulley. Remove fan belt.Repair
Inspect belts for:1 Cracking2 Rupture3 Tears4 Burning5 Gouging6 Wear7 Internal Cord Failure8 Cuts9 Peeling, Fraying, ChewingDo not reuse a damaged belt. Install a new belt.Installation
Fig. 2-Install Fan BeltPut fan belt over fan (1, Fig. 2). Put fan belt over crankshaft pulley (2) and alternator pulley (3). Position fan belt in pulley grooves.Adjust fan belt tension (Group 9010).Crankshaft Pulley
Removal
Remove fan belt from pulley (Group 0429).
Fig. 3-Cap Screw and WasherRemove cap screw and washer (Fig. 3) holding crankshaft pulley on crankshaft. IMPORTANT: On six cylinder engines the crankshaft pulley is also a vibration damper. Do not drop or hammer on vibration dampers.
Fig. 4-D01200AA PullerUsing D01200AA Puller (Fig. 4), pull crankshaft pulley off crankshaft.Repair
Inspect pulley sheaves for cracks and wear. Replace pulley if damaged.For vibration damper repair, see Group 0401.Installation
Position crankshaft pulley on crankshaft.Put washer on cap screw. Install cap screw through crankshaft pulley into crankshaft.
Fig. 5-Cap ScrewTighten cap screw (Fig. 5) to 85 lb-ft (115 N m) (12 kg-m).Install fan belts (Group 0429).Adjust fan belt tension (Group 9010).