101491-0558 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014910558 8970318701


 

Information injection-pump assembly

ZEXEL 101491-0558 1014910558
ISUZU 8970318701 8970318701
101491-0558 INJECTION-PUMP ASSEMBLY
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Service parts 101491-0558 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101049-8720
3. GOVERNOR 105931-9471
4. SUPPLY PUMP 105210-5140
5. AUTOM. ADVANCE MECHANIS 105671-0160
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5122
11. Nozzle and Holder 8-97021-703-1
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105048-3352
14. NOZZLE 105017-0610
15. NOZZLE SET

Include in #1:

101491-0558 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101491-0558 1014910558
ISUZU 8970318701 8970318701


Zexel num
Bosch num
Firm num
Name
101491-0558 
 
8970318701  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   12.2
Pump speed r/min   1050 1050 1050
Average injection quantity mm3/st.   57.1 55.5 58.7
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   325 325 325
Average injection quantity mm3/st.   13.3 12 14.6
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(12.2)
Pump speed r/min   1050 1050 1050
Average injection quantity mm3/st.   57.1 56.1 58.1
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.15
Pump speed r/min   1750 1750 1750
Average injection quantity mm3/st.   68 64 72
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   1530--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1480
Advance angle deg.   0.3
Timer adjustment_03
Pump speed r/min   1775
Advance angle deg.   4.5 4 5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101491-0558
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=F44 N1=100r/min
----------

Speed control lever angle

Test data 101491-0558
F:Full speed I:Idle (1)Use the hole at R = aa (2)Set the idle side stopper bolt so that speed = bb and rack position = cc (at delivery). (3)Stopper bolt set position 'H'
----------
aa=50mm bb=100r/min cc=(12.2)mm
----------
a=(23.5deg) b=27.5deg+-5deg c=(33deg)+-3deg

Stop lever angle

Test data 101491-0558
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

Test data 101491-0558
(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=(100deg)




Information:

Turbocharger
Turbocharger
(1) Turbine wheel. (2) Compressor wheel. (3) Exhaust outlet. (4) Air inlet. (8) Oil inlet passage. (9) Oil outlet. (10) Exhaust inlet.The turbocharger is installed on the exhaust manifold. All the exhaust gases from the engine go through the turbocharger.The exhaust gases enter exhaust inlet (10) and go through the blades of turbine wheel (1), causing the turbine wheel and compressor wheel (2) to turn.When the compressor wheel turns, it pulls filtered air from the air cleaner through air inlet (4). The air is put in compression by action of the compressor wheel and is pushed to the inlet manifold of the engine.When engine load increases, more fuel is injected into the engine cylinders. The volume of exhaust gas increases, which causes the turbocharger turbine wheel and compressor wheel to turn faster. The increased rpm of the compressor wheel increases the quantity of inlet air. As the turbocharger provides additional inlet air, more fuel can be burned. This results in more horsepower from the engine at higher altitudes.Maximum rpm of the turbocharger is controlled by the high idle speed setting and the height above sea level at which the engine is operated.The bearings for the turbocharger use engine oil for lubrication. The oil comes in through oil inlet (8) and goes through passages in the center section for lubrication of the bearings. Oil from the turbocharger goes out through oil outlet (9) in the bottom of the center section and goes back to the engine oil pan.The turbocharger allows the engine to run properly at high altitudes where the air is leaner. In this application, the turbocharger does not give more power. It compensates for leaner air.Crankcase Ventilation System
The air intake system is also equipped with a crankcase ventilation system, or breather. The piston intake stroke pulls in atmospheric air to the crankcase area.
Crankcase Ventilation
(1) Ventilation hose. (2) Breather.The fumes in the crankcase flow through a passage of the engine block to the valve cover, through hose (1) and breather (2) to the atmosphere.Electrical System
The electrical system is a 12 volt, negative ground system that has two basic circuits. They are the starting circuit and the charging circuit, which includes the low amperage circuit with warning lights and gauges. Some of the electrical components are used in more than one circuit.The starting circuit is in operation only when the key start switch is turned to the START position. In the starting circuit, the transmission neutral/switch must be closed before the starter solenoid is energized (electrical energy).The charging circuit is in operation when the engine is running. The alternator in the charging circuit gives current to the electrical system. The battery keeps the storage of the current. A voltage regulator in the circuit, on the alternator housing, controls the amount of current output to the battery. The voltmeter in the circuit shows system voltage.Reference: For a complete electrical schematic, see Schematics For Backhoe Loader Electrical System, Form No. SENR3165; Backhoe Loader Electrical System (With Roading Arrangement), Form No. SENR3924;

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