101401-4280 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014014280 8970610280

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-4280 1014014280

ISUZU 8970610280 8970610280

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Cross reference number

ZEXEL 101401-4280 1014014280

ISUZU 8970610280 8970610280

Zexel num

Bosch num

Firm num

Name

101401-4280
101401-4281

8970610280 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1-T * K

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 11.6

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 72.1 70.5 73.7

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 325 325 325

Average injection quantity mm3/st. 12.1 10.8 13.4

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(11.6)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 72.1 71.1 73.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 82.6 79.4 85.8

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 53.6 49.6 57.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position (R1+0.1)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 76.1 72.9 79.3

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 116 116 124

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1000+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

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)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=D40
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Speed control lever angle

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

----------
a=3.5deg+-5deg b=27deg+-3deg

Stop lever angle

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

----------
a=45deg+-5deg b=29deg+-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.
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N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
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Ra=R1(11.6)mm Rb=(R1-0.5)mm Pa=87.7+-2.7kPa(658+-20mmHg) Pb=74.8+-0.7kPa(561+-5mmHg) Q1=72.1+-1cm3/1000st Q2=64.7+-1.6cm3/1000st

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=15deg
----------
a=(100deg)

Information:

Start By:a. remove engine and transmissionb. remove oil pumpc. remove crankshaft rear seal 1. Fasten the engine to tool (A) at the flywheel end as shown.2. Remove bridge (1) and the seals. 3. Remove rear main bearing cap (2). Be sure the location is marked on the main bearing cap before it is removed. The stamped location number is toward the camshaft. 4. Remove upper bearing half (3) with an approved bearing removal tool.
Do not turn the crankshaft in a counterclockwise direction because the tab of the bearing can be pushed between the crankshaft and the engine block. This will cause damage to the crankshaft and engine block.
5. Turn the crankshaft clockwise, as seen from the flywheel, to remove bearing upper half (3). 6. Remove bearing lower half (4) from rear main bearing cap (2). 7. Put the bearing upper half (3) in position on the crankshaft, and use the removal tool to rotate the bearing into position. Turn the crankshaft in a counterclockwise direction to engage bearing tab with the engine block. 8. Install the bearing lower half in the main bearing cap.9. Put a piece of Plastigage (5) across the crankshaft main bearing face. Install main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.10. Put the main bearing cap in position. Put clean engine oil on the threads of the main bearing cap bolts, and tighten them finger tight.11. Tighten the main bearing cap bolts to a torque