101401-4751 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014014751 8971058390

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-4751 1014014751

ISUZU 8971058390 8971058390

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Cross reference number

ZEXEL 101401-4751 1014014751

ISUZU 8971058390 8971058390

Zexel num

Bosch num

Firm num

Name

101401-4751

8971058390 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 11.6

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 67.5 65.9 69.1

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 9.7+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 10.5 9.2 11.8

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(11.6)

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 67.5 66.5 68.5

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. 86 82 90

Fixing the lever *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

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.
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T1=J75
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Speed control lever angle

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

----------
a=42deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
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aa=64mm
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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.
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P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=440r/min Ra=9.1+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
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L=(5)mm

0000001601 RACK SENSOR

Rack sensor adjustment (1)These types of rack sensors do not need adjustment. Confirm the output as described below. (2)Mount the rack sensor main body to the pump main body. (3)Measure the Vist at pump speed N1 and rack position Ra.
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N1=1600r/min Ra=R1(11.6)+0.25mm
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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
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aa=7deg
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a=(60deg) b=(85deg)

Information:

a) Remove by screwing flywheel attaching bolts uniformly into the bolt holes for removal. Pull out using the special tool, Gear Puller. Do not remove the gear by striking it. b) Heat the gear to about 100°C by a heater, etc. Aligning the crankshaft dowel pin with the dowel pin hole in the gear, insert the shaft into the gear, lightly striking the gear end face with a soft hammer.c) Install the sleeve using the special tool, Oil Seal and Sleeve Installer. [Refer to Item (2) - (b), Section 5.1.3.](3) Reassembly Reassembly
(a) Installation of oil jet (excluding 6D14, 6D15) Fix the oil jet aligning with the locating pin and tighten the check valve to specified torque. Bend lock washer onto the check valve to prevent it from turning.(b) Installation of thrust plate and main bearing 1. Install the thrust plate with its side having no oil groove toward the crankcase.2. Line up the lug of main bearing with the lug groove in crankcase. Note that the upper main bearing has an oil hole, which must not be confused with the lower bearing.3. Apply engine oil to all sliding surfaces.(c) Installation of main bearing cap 1) Fit the lower main bearing into the main bearing cap. At the time, make sure that the main bearing lug is aligned with the main bearing cap lug groove.2) Install also the thrust plate onto the main bearing cap in the rear-end position.3) Make sure that the main bearing cap lug groove and crankcase lug groove are on the same side. 1. Face the side of thrust plate having no oil groove toward the rear end of the crankcase and toward the main bearing cap.2. Use thrust plates of the same size for the rear end of the crankcase and main bearing cap rear end. 4) Tighten the main bearing cap bolt to specification. Then, make sure that the crankshaft turns smoothly by hand.5) Measure the crankshaft end play to determine if it is within the nominal value [Refer to Item (1) - (c), Section 5.1.4.].(d) Reassembly of piston and connecting rod 1) Assemble the piston and the connecting rod, ensuring correct direction as illustrated.2) Insert the piston pin to couple the piston and connecting rod. Mount the snap ring to hold the piston pin in position. The piston pin is a clearance fit in the piston. If the piston pin is hard to fit, heat the piston with a piston heater or hot water. 1. Keep the piston weight difference for one engine within 10 g.2. Use connecting rod assembly of same weight mark for an engine.3. Check to see that the size mark of the piston is same as that of the cylinder liner.4. Apply engine oil to sliding surfaces. 3) The connecting rod bolts do not normally need removal; however, where replacement is necessary for damaged bolt, install new bolts by using the following procedures. Make sure that the connecting rod bolt hole is free from damage and burrs. Then,