101401-4990 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014014990 8971182910

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-4990 1014014990

ISUZU 8971182910 8971182910

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Cross reference number

ZEXEL 101401-4990 1014014990

ISUZU 8971182910 8971182910

Zexel num

Bosch num

Firm num

Name

101401-4990
101401-4991

8971182910 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 12.2

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 68.5 66.9 70.1

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 9.8+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 15.5 14.2 16.8

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(12.2)

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 68.5 67.5 69.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.05

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 78.5 74.5 82.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.45

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 45.7 41.7 49.7

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)Tolerances for racks not indicated: +-0.05mm.
----------
T1=K19
----------

Speed control lever angle

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

----------
a=41deg+-5deg b=34deg+-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 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.
----------
N1=1600r/min Ra=R1(12.2)+0.05mm
----------

0000001601 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=9.2+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)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=7deg
----------
a=(60deg) b=(85deg)

Information:

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Rotation as seen from drive end ... ClockwiseMinimum speed with no load ... 6300 rpmMaximum speed with no load ... 8400 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 23V ... 60AMaximum with solenoid at 23V ... 75AClearance between pinion and housing (pinion clearance) ... 9.1 mm (.36 in)(1) Torque for terminal nuts ... 27 to 34 N m (20 to 25 lb ft)(2) Torque for screws holding nose housing to lever housing ... 23.7 6.1 N m (17 4.5 lb ft)8C3651 24V (Delco-Remy Number 1993804)
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Rotation as seen from drive end ... ClockwiseMinimum speed with no load ... 6000 rpmMaximum speed with no load ... 10260 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 23V ... 60AMaximum with solenoid at 23V ... 118AClearance between pinion and housing (pinion clearance) ... 8.3 to 9.9 mm (.33 to .39 in)(1) Torque for terminal nuts ... 27 to 34 N m (20 to 25 lb ft)3T2772 24V (Delco-Remy Number 1113540)
Rotation as seen from drive end ... ClockwiseMinimum speed with no load ... 6850 rpmMaximum speed with no load ... 11250 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 23V ... 48AMaximum with solenoid at 23V ... 76AClearance between pinion and housing (pinion clearance) ... 8.3 to 9.9 mm (.33 to .39 in)(1) Torque for terminal nuts ... 27 to 34 N m (20 to 25 lb ft)3T4581 24V (Delco-Remy Number 1113583)
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Rotation as seen