101401-0930 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014010930 8943641730

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-0930 1014010930

ISUZU 8943641730 8943641730

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Service parts 101401-0930 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8730

3. GOVERNOR 105931-6151

4. SUPPLY PUMP 105210-4860

5. AUTOM. ADVANCE MECHANIS 105671-0070

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4724

11. Nozzle and Holder 8-94479-578-3

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3352

14. NOZZLE

105017-0640

15. NOZZLE SET

Include in #1:

101401-0930 as INJECTION-PUMP ASSEMBLY

101603-2150 as _

Cross reference number

ZEXEL 101401-0930 1014010930

ISUZU 8943641730 8943641730

Zexel num

Bosch num

Firm num

Name

101401-0930
101401-0931

8943641730 ISUZU

INJECTION-PUMP ASSEMBLY
4BG1 *

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 3.6 3.55 3.65

Rack position
Point A R=A

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 900 900 900

Average injection quantity mm3/st. 70.5 68.9 72.1

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. 9.5 8.2 10.8

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 900 900 900

Average injection quantity mm3/st. 70.5 69.5 71.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1525 1525 1525

Average injection quantity mm3/st. 83.2 80 86.4

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(11.2)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 53.8 50.6 57

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 77 69 85

Fixing the lever *

Timer adjustment

Pump speed r/min 1370--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1320

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=D65
----------

Speed control lever angle

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

----------
a=2.5deg+-5deg b=33.5deg+-3deg

0000001501 FICD

Negative pressure port A (B) Screw 1. FICD adjustment (1)Set the clearance between the actuator and the speed lever at L1. (2)Fully screw in screw B. (3)Apply P1 to negative pressure port A and gradually tighten screw B. (4)Fix the screw (B) at pump speed N1 and rack position R1. (Tightening torque = T1) (5)Apply P2 to negative pressure port A and confirm that the FICD operates normally.
----------
L1=(3)mm P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) N1=600r/min R1=9.2+-0.1mm
----------

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=12deg
----------
a=(100deg)

Information:

Installation of Oil Seal Case (Option)
(1) Coat the outside surface of the oil seal with engine oil.(2) Install the oil seal on the oil seal case.(3) Coat the lip of the oil seal with engine oil.(4) Install the O-ring into the oil seal case, and install the oil seal case on the flywheel housing. The oil seal case must be installed with the "Q" mark facing up.(5) Secure the oil seal case with the bolts.
Installation of oil seal case (option)Installation of Flywheel
(1) Install the flywheel to the crankshaft by aligning the hole with the dowel pin on the back-end of the crankshaft.(2) Place the washer and tighten the four bolts to the specified torque.
Installation of flywheelMeasurement of Flywheel Runout
Measure the flywheel runout with the flywheel installed to the crankshaft. If the standard value is exceeded, check the bolts for tightening condition and the mounting face for adhesion of foreign particles.
Measurement of face runout and circular runoutCylinder Head and Valve Mechanisms
Installation of Valve Stem Seal
(1) Apply engine oil to the valve stem, and insert it into the valve guide.(2) Place a new stem seal on the valve guide.(3) Using the stem seal installer, install the stem seal to the valve guide, making use of the valve stem as a guide.
Installation of valve stem sealInstallation of Valves and Valve Springs
(1) Place the valve spring and retainer on the valve guide, and install the valve cotter using the valve spring pusher.
Excessive compression of the valve spring can cause the retainer to contact the stem seal and damage the seal.
Installation of valve and valve spring(2) Using a soft-faced hammer, tap the top of the valve stem several times to make sure that the spring and valve cotter are securely installed.
Confirmation of secure valve cotter installationInstallation of Cylinder Head Gasket
(1) Make sure that the top face of the crankcase and piston upper surfaces are clean and free of dust.(2) Place a new gasket of the crankcase, making sure that the dowel pins on the top face of the crankcase enter the holes in the gasket.
Do not use a liquid gasket.
Installation of cylinder head gasketInstallation of Cylinder Head
Place the cylinder head on the head gasket, making sure that the dowel pins on the top face of the crankcase enters the holes in the cylinder head.
Installation of cylinder headTightening of Cylinder Head Bolts
Tighten the cylinder head bolts, following the tightening sequence shown in the diagram two or three times before reaching the specified torque.
Cylinder head bolt tightening sequenceAssembly of Rocker Arm and Rocker Shaft Assembly
When installing the rocker arms, make sure that the shaft assembly marks face the front of the engine, as shown in the diagram. After the assembly, make sure that the rocker arms move smoothly.
Assembly of rocker shaft assemblyInstallation of Pushrods
(1) Insert the pushrods in the cylinder head through the pushrod holes.(2) Make sure that the ball end of each pushrod rests securely on the curved surface of the tappet.Installation of Rocker Shaft Assemblies
(1) Install the valve caps.(2) Tighten the rocker shaft