101481-0152 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014810152 8970106482

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101481-0152 1014810152

ISUZU 8970106482 8970106482

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Cross reference number

ZEXEL 101481-0152 1014810152

ISUZU 8970106482 8970106482

Zexel num

Bosch num

Firm num

Name

101481-0152
101481-0153

8970106482 ISUZU

INJECTION-PUMP ASSEMBLY
4BD2 * 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 2.8 2.75 2.85

Rack position
Point A R=A

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 12.1

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 76.8 75.2 78.4

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 9.5+-0.5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 9 7.7 10.3

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(12.1)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 76.8 75.8 77.8

Basic *

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.5

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 72.4 68.4 76.4

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 15)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 67.5 63.5 71.5

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_06

Adjusting point D

Rack position R2-0.3

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 60.8 56.8 64.8

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 93 93 109

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R2-0.3

Boost pressure kPa 6.7 6.7 9.4

Boost pressure mmHg 50 50 70

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R2(R1-0. 15)

Boost pressure kPa 10.7 10.7 10.7

Boost pressure mmHg 80 80 80

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 3.9 3.4 4.4

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)Boost compensator stroke: BCL
----------
T1=F86 BCL=0.3+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)At M/S adjustment, confirm that M/S turns ON when speed lever is returned from full to idle and gap between speed lever and idle side stopper bolt is aa. Confirm that M/S turns OFF when speed lever is again returned from full to idle at gap bb.
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aa=0.1mm bb=0.25mm
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a=6.5deg+-5deg b=32deg+-3deg

Stop lever angle

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

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a=45deg+-5deg b=29deg+-5deg

0000001501 ACS

(A) Aneroid compensator (B) Set screw (C) Boost pressure inlet (D) Rack positioning screw (E): Aneroid compensator main body (F) Boost compensator spring (G): Aneroid compensator spring (H): Adjusting notch (I) Push rod 1. Instructions for adjusting the boost compensator with the aneroid compensator (1)Select a pushrod to obtain L1 at full boost. (2)Remove the aneroid compensator main body. (3)Adjust the booster compensator stroke by turning the screw at (D. (4)Adjust the beginning of boost compensator operation by turning the notch at (H). (5)Install the aneroid compensator at full boost state. (6)Turn (B)'s set screw so that the distance between the snapring and the body is L2. (7)Screw in the aneroid compensator main body and adjust the point where it comes into play.
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L1=24+-0.5mm L2=1.5+-0.5mm
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0000001601 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 1. Adjustment of the aneroid compensator itself and the adjustment after 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 (A) to obtain the performance shown in the graph (to obtain L1). (3)Adjust the (D) spacer so that dimension L2 is obtained. (4)As there is hysterisis, measure when the absolute pressure drops. (5)Hysterisis must not exceed rack position = h1.
----------
N1=950r/min L1=1.5+-0.5mm L2=24+-0.5mm h1=0.15mm
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Ra=R1(12.1)mm Rb=R1-0.25mm P1=74.6+-2.7kPa(560+-20mmHg) P2=61.6+-0.7kPa(462+-5mmHg) Q1=76.8+-1cm3/1000st Q2=(70.7)+-2cm3/1000st

0000001701 FICD

(a) actuator (B) Screw (c) Nut 1. FICD adjustment (1)Set the clearance between the actuator rod and speed lever to approx. L1. (2)Loosen nut (C) and fully screw in the actuator (A)'s screw (B). (3)Apply negative pressure P1 to the actuator (A) and fully screw in screw (B). (4)Set the pump speed at N1 (5)Set the rack position at R1. (6)Tighten the actuator (A)'s screw (B) and fix using the nut (C). (7)Apply P2 to negative pressure port A and confirm that the FICD operates normally.
----------
L1=(3)mm P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) N1=450r/min R1=9.3+-0.1mm
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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=8deg
----------
a=(100deg)

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Table 1
Existing Part Number New Part Number Description
459-7216 471-6029 DEF Injector & Mounting Gp
540-0883 554-8955 24V DEF Pump Software
481-5823 554-8956 12V DEF Pump Software Refer to Disassembly and Assembly, DEF Injector and Mounting - Remove and Install for the correct procedure to install the new DEF injector.Refer to Troubleshooting, ECM Software - Install for the correct procedure to install the new software.