101401-4290 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014014290 8970337630

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-4290 1014014290

ISUZU 8970337630 8970337630

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Service parts 101401-4290 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8000

3. GOVERNOR 105931-9490

4. SUPPLY PUMP 105210-5350

5. AUTOM. ADVANCE MECHANIS 105676-5030

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5663

11. Nozzle and Holder 8-97114-016-0

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3673

14. NOZZLE

105017-1460

15. NOZZLE SET

Include in #1:

101401-4290 as INJECTION-PUMP ASSEMBLY

101642-2010 as _

Cross reference number

ZEXEL 101401-4290 1014014290

ISUZU 8970337630 8970337630

Zexel num

Bosch num

Firm num

Name

101401-4290
101401-4291

8970337630 ISUZU

INJECTION-PUMP ASSEMBLY
4HF1 * 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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 4.1 4.05 4.15

Rack position
Point A R=A

Beginning of injection position
Governor 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 12.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 77.6 76 79.2

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 285 285 285

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.6)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 77.6 76.6 78.6

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 88.4 84.4 92.4

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 80 80 112

Fixing the lever *

Timer adjustment

Pump speed r/min 1375--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1325

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 3.3 2.8 3.8

Timer adjustment_04

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=H43
----------

Speed control lever angle

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

----------
a=43deg+-5deg b=37deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg

0000001501 FICD

(A) applied negative pressure (B) Screw (c) Nut 1. Set the actuator as described below. (1)Confirm that there is clearance between the actuator lever and the speed lever. (2)Loosen the nut (C). (3)Push in the screw (B). (4)Apply P1 from the actuator (A) part. (5)Pull out the screw (B) slowly. (6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra. (7)Torque the nut (C) to T1. (8)Apply P2 several times. (9)Confirm that the actuator functions normally. (10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=440r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Stamping position on the A/T outer rim (4)Pump bracket check hole position. (5)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1. (6)B.T.D.C.: aa
----------
aa=10deg
----------
a=(60deg) b=(85deg)

Information:

1. Remove tube and elbow (1).2. Remove tube and oil sump (2).
Turn the crankshaft so the piston is down, and remove the ridge of carbon with emery cloth from each liner before removing the pistons. Damage can be caused to the pistons during removal by the build up of carbon if it is not removed.
3. Turn the crankshaft until the connecting rod cap to be removed is at bottom center.4. Remove connecting rod cap (3) from the connecting rod.
Put identification marks on the connecting rod caps as to their location in the engine. Keep the caps with their respective piston.
5. Push the connecting rod and piston away from the crankshaft until the piston rings are above the cylinder liner. Remove piston (4) and the connecting rod from the engine.
Use tape to hold the bearing halves together and to identify the number of the cylinder.
Install Pistons
1. Turn the crankshaft until the bearing journal for the piston to be installed is at bottom center.2. Put clean engine oil on the crankshaft journal and on the inside of the cylinder liner.3. Put clean engine oil on the piston rings and connecting rod bearings.4. Move the piston ring gaps 180° apart.5. Use tool (A), and put the piston and connecting rod in its original location in the cylinder block. Be sure the numbered side of the connecting rod is toward the right side of the engine. This is when viewed from the front of the engine.
Be sure the connecting rod bolts do not contact the crankshaft journal during installation of the piston.
6. Use a hammer handle, and lightly tap the piston into position.
When the connecting rod caps are installed, make sure the number on the side of the cap is next to the same number on the connecting rod. The numbers must be away from the camshaft.
7. Install connecting rod cap (1) and the nuts which hold it. Tighten the nuts to a torque value of: Cadmium plated nuts (silver color) - 100 N m (75 lb.ft).Phosphated nuts (dull black color) - 130 N m (95 lb.ft.).8. Follow the same procedure for installation of the remainder of the pistons. 9. Install tube and elbow (2). Install tube and oil sump (3).End By:a. install oil panb. install cylinder head assemblyDisassemble Pistons
Start By:a. remove pistons Put identification marks on all parts for correct assembly.1. Remove rings (1) from piston (2) with tool (A). 2. Remove retaining ring (3) from each side of the piston with tool (B).3. Remove pin (4) and connecting rod (5) from piston (2). 4. Remove bolts (7) from the connecting rod.5. Remove bushing (6) from connecting rod (5) with tool group (C).6. Check all of the parts of the piston and rod for damage and wear. See Specification for minimum and maximum wear dimensions.Assemble Pistons
1. Install bolts (1) in connecting rod (2).2. Install the bushing in connecting rod (2) with tool group (A) and a press. Hone the bushing to the correct size. See Specifications for the correct dimension. 3.