101491-0490 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014910490 8970110150

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-0490 1014910490

ISUZU 8970110150 8970110150

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Cross reference number

ZEXEL 101491-0490 1014910490

ISUZU 8970110150 8970110150

Zexel num

Bosch num

Firm num

Name

101491-0490
101491-0491

8970110150 ISUZU

INJECTION-PUMP ASSEMBLY
4BE1 *

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 3.8 3.75 3.85

Rack position
After adjusting injection quantity. 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 13.2

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 74.1 72.5 75.7

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 300 300 300

Average injection quantity mm3/st. 10.2 8.9 11.5

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(13.2)

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 74.1 73.1 75.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.45

Pump speed r/min 1750 1750 1750

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 100 100 100

Average injection quantity mm3/st. 92 92 124

Fixing the lever *

Timer adjustment

Pump speed r/min 1550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1500

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1800

Advance angle deg. 4.5 4 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. (3)At delivery (at R = A, N = N1)
----------
T1=E68 N1=100r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)Set the idle side stopper bolt at speed = aa and rack position = bb (at delivery)
----------
aa=100r/min bb=R1(13.2)mm
----------
a=(8deg) b=35deg+-3deg c=2.5deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=45deg+-5deg b=29deg+-5deg

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131154-1820 ST=A260 L1=1mm L2=3.8+-0.05mm a1=+-14% a2=+-2.5%
----------

0000001601 FICD

1. FICD adjustment (1)FICD adjustment not necessary. (2)Set the clearance between the actuator rod and speed lever to approx. L1.
----------
L1=3+1mm
----------

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=15deg
----------
a=(90deg)

Information:

3T6352 Alternator 24V 35A (Delco-Remy Number 1117647)
Load battery with a carbon pile (6V4930 Battery Load Tester) to get maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionOutput voltage ... 27.5 1.0VSpeed for testing (rpm) ... 5000Output (hot) ... 35APositive output terminal torque ... 6.2 to 8.0 N m (55 to 71 lb in)(1) Ground terminal torque ... 1.7 to 2.9 N m (15 to 26 lb in)(2) Shaft nut torque ... 95 to 110 N m (70 to 80 lb ft) 3T6354 Regulator (Delco-Remy Number 1116405) - Inside Alternator. For use with 3T6352 Alternators
Voltage setting ... No AdjustmentPermissible voltage range ... 26 to 30VBosch
7N9720 Alternator 24V 35A (Bosch Number 0-122-469-001)
Load battery with a carbon pile (6V4930 Battery Load Tester) to get maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 5000Output voltage ... 27.5 1.0VOutput (hot) ... 35A(1) Torque for pulley nut ... 95 to 110 N m (70 to 80 lb ft)(2) Torque for output terminal B+ ... 17 to 22 N m (13 to 16 lb ft)Torque for ground terminal ... 2.1 to 2.8 N m (19 to 25 lb in) 9G7567 Regulator (Bosch Number 1-197-011-000)-under alternator cover. For use with 7N9720 Alternators.
Voltage setting ... No AdjustmentPermissible voltage range ... 26.7 to 28.3VNippondenso
9G4574 24V 35A (Nippondenso Number 100211-0860)
Load battery with a carbon pile (6V4930 Battery Load Tester) to get maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 5000Output voltage ... 27.5 1.0VOutput (hot) ... 35A(1) Torque for pulley nut ... 95 to 110 N m (70 to 80 lb ft)(2) Torque for output terminal ... 22 to 37 N m (16 to 27 lb ft)(3) Torque for ground terminal ... 3.4 to 5.4 N m (31 to 49 lb in) 7T2798 Regulator (Nippondenso Number 126000-0380) - Inside Alternator. For use with 9G4574 Alternators.
Voltage setting ... No adjustmentPermissible voltage range ... 26.5 to 28.5V