101491-0510 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014910510 8970140760

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-0510 1014910510

ISUZU 8970140760 8970140760

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Cross reference number

ZEXEL 101491-0510 1014910510

ISUZU 8970140760 8970140760

Zexel num

Bosch num

Firm num

Name

101491-0510
101491-0560

8970140760 ISUZU

INJECTION-PUMP ASSEMBLY
4BE1 * 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 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=E77 N1=100r/min
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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=(44deg)+-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%
----------

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:

2. Disconnect the fuel lines from fuel transfer pump (1).3. Remove two bolts (2) and fuel transfer pump (1). 4. Be sure O-ring seal (3) is in position on the fuel transfer pump and put clean oil on the O-ring seal.5. Put the fuel transfer pump in position on the fuel injection pump and install the two bolts that hold it in place.6. Connect the fuel lines to the fuel transfer pump.7. Open the fuel shutoff valve at the fuel tank.Disassemble Fuel Transfer Pump
start by:a) remove fuel transfer pump
Cover (2) is under spring tension.
1. Carefully remove bolts (1) and cover (2) from the fuel transfer pump. 2. Remove spring (3), valve (4) and O-ring seals (5) from the cover. 3. Remove springs (6) and (7) from the pump housing. 4. Remove sleeve (8) from the pump housing. 5. Remove sleeve (12), piston (16), O-ring seal (11) and piston (9) from sleeve (8). Remove plate (15), valve (10) and seal (14) from piston (9). Remove O-ring seal (13) from sleeve (8). 6. Remove O-ring seal (17) from the pump housing. 7. Push guide (18) through the pump housing and remove guides (23) and (18) together. Remove rod (20), guide (23), O-ring seal (19) and tappet (21) from guide (18). Remove ring (22) from tappet (21). 8. Remove connector (24), valve (26) and seal (25) from the pump housing. 9. Remove plug (30), spring (28), valve (29) and seal (27) from the pump housing.Assemble Fuel Transfer Pump
1. Clean all parts and be sure all passage are open. 2. Be sure the O-ring seal is in position on plug (4) and put 4L7464 Silicone Grease on the O-ring seal. Valves (2 and 6) must be installed as shown for the pump to work correctly.3. Install seal (1), valve (2), spring (3) and plug (4) in the pump housing as shown. Tighten plug (4) to a torque of 20 7 N m (15 5 lb.ft.). 4. Be sure the O-ring seal is in position on connector (7) and put 4L7464 Silicone Grease on the O-ring seal.5. Install seal (5), valve (6) and connector (7) in the pump housing as shown. Tighten connector (7) to a torque of 55 10 N m (40 7 lb.ft.). 6. Install the ring on tappet (8). Install tappet (8), O-ring seal (12), guide (9) and rod (10) in guide (11). Put 4L7464 Silicone Grease on O-ring seal (12). Install guides (11) and (9) as a unit in the pump housing as shown. 7. Install O-ring seal (13) in the pump housing and put 4L7464 Silicone Grease on the O-ring seal. 8. Install seal (15), valve (19) and plate (16) in piston (14) as shown. Install piston (14), O-ring seal (17), piston (20) and guide (21) in guide (18) as shown. Install the O-ring seal on guide (18) and put 4L7464 Silicone Grease on O-ring seal (17) and the O-ring seal on guide (18). 9. Install guide (18) in the pump housing as shown.