101401-4350 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014014350 8970758660


 

Information injection-pump assembly

ZEXEL 101401-4350 1014014350
ISUZU 8970758660 8970758660
101401-4350 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101401-4350 1014014350
ISUZU 8970758660 8970758660


Zexel num
Bosch num
Firm num
Name
101401-4350 
101401-4351 
 
8970758660  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   11.8
Pump speed r/min   960 960 960
Average injection quantity mm3/st.   74.7 73.1 76.3
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.   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(11.8)
Pump speed r/min   960 960 960
Average injection quantity mm3/st.   74.7 73.7 75.7
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.25
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   89.8 85.8 93.8
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   76 76 108
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

Test data 101401-4350
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=H58
----------

Speed control lever angle

Test data 101401-4350
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=41deg+-5deg b=38deg+-3deg

Stop lever angle

Test data 101401-4350
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=1100r/min Ra=9.2+-0.1mm
----------

0000001601 FICD

Test data 101401-4350
(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=540r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm

Timing setting

Test data 101401-4350
(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:

Safety is everyone's business and is basically the use of good common sense. A general guide of safety precautions are given below, but each installation has its own peculiarities which cannot always be predicted and covered by established rules. Past experience and common sense are needed for the necessary safety measures. Attention to safety will help avoid serious accidents. Be alert. Watch for hazards. Use preventive measures. Correct deficiencies immediately.The following safety precautions are a general guide to safe operation:1. To prevent personal injury, install guards over all exposed rotating parts.2. To prevent hearing damage, wear ear protective devices if working inside an enclosed engine room with engine running.3. To prevent head injury, wear safety hat when working in the area of overhead equipment.4. Wear safety glasses and shoes as required. 5. Do not wear loose clothing whenever working around engines or machinery.6. Wipe up spilled oil, fuel or coolant.7. Keep batteries in a well ventilated area. Do not smoke around batteries. Hydrogen gas, which is present in the area of the batteries, is highly explosive.8. Provide adequate and safe waste oil disposal.9. Store oily rags in fireproof containers. Don't leave rags on engine.
When using pressure air, wear safety glasses and protective clothing. Maximum air pressure, used for cleaning, must be below 30 PSI (2 kg/cm2).
10. Remove all tools, electrical cords and other loose items from the engine before starting.11. Disconnect and tape the battery ground lead before working on an engine to prevent accidental starting. Be sure an automatic start-stop system cannot operate and start the engine while working on it.12. Do not attempt repairs you do not understand. Follow instructions.13. Stop engine before adjusting or repairing engine or driven equipment.14. Remove radiator cap slowly. Cooling systems can be pressurized and hot fluid will flash to steam as pressure is removed.15. Never start an engine with the governor linkage disconnected.16. Replace or repair broken or damaged equipment. Use proper tools.17. Do not smoke while refueling. Observe NO SMOKING signs.18. Never store flammable liquids near the engine.19. All electrical equipment must be grounded according to local building codes.20. Check all connections periodically for tightness and insulation.21. Insulate all connections and disconnected wires.22. Do not use carbon tetrachloride fire extinguishers. Fumes are toxic and the liquid has a deteriorating effect on insulation. 23. Do not touch the heat sink on the generator regulator when the generator is running. It is electrically "hot".24. Do not work on electrically "hot" equipment.25. Always disconnect the engine starter circuit when working on the generator.26. Hot engine oil can cause burns when drained. Allow the oil to cool below 140°F or provide protection when draining the hot oil.27. Never remove a plug to check pressure with the engine running. Shut down the engine and assure there is no pressure before removing plug.28. When starting an engine after repair, make provisions for shutting off air supply in case there is an overspeed on start up.29. Never look into an open cylinder port and turn over

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