101491-0630 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014910630 8970331530

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-0630 1014910630

ISUZU 8970331530 8970331530

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Service parts 101491-0630 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8500

3. GOVERNOR 105931-8380

4. SUPPLY PUMP 105220-5950

5. AUTOM. ADVANCE MECHANIS 105622-1590

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5121

11. Nozzle and Holder 5-15300-115-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4740

15. NOZZLE SET

Include in #1:

101491-0630 as INJECTION-PUMP ASSEMBLY

101605-3210 as _

Cross reference number

ZEXEL 101491-0630 1014910630

ISUZU 8970331530 8970331530

Zexel num

Bosch num

Firm num

Name

101491-0630

8970331530 ISUZU

INJECTION-PUMP ASSEMBLY
4BC2 * 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

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 3.4 3.35 3.45

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 10.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 49.2 47.6 50.8

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 -

Rack position 9.9+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9.5 8 11

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.2)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 49.2 48.2 50.2

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 46.5 43.3 49.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.1

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 39.8 36.6 43

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 57.5 52.5 62.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1300--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1250

Advance angle deg. 0.6

Timer adjustment_03

Pump speed r/min 1900

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)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=55
----------

Speed control lever angle

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

----------
a=5.5deg+-5deg b=40deg+-3deg

Stop lever angle

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

----------
a=35deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when 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 the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=1100r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.2)mm Rb=(R1-0.4)mm Pa=97.3+-2.7kPa(730+-20mmHg) Pb=79.4kPa(596mmHg) Q1=49.2+-1cm3/1000st Q2=41.1+-1cm3/1000st

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=16deg
----------
a=(100deg)

Information:

(1) Cylinder head bolts and nuts: 1. Put clean engine oil on the threads of bolts and nuts. Tighten bolts and nuts (cold), numbers 1 thru 32 in order shown, to a torque of 155 N m (115 lb.ft.)2. Tighten small bolts (cold), numbers 33 thru 38, to a torque of ... 38 N m (28 lb.ft.)Retighten the cylinder head bolts and nuts after the engine has run and the coolant temperature is no less than 77°C (170°F) as follows:a. If the bolts and nuts move before the correct torque (above) is reached, tighten the bolts and nuts (hot) to the torques that follow: No. 1 thru 32 ... 142 N m (105 lb.ft.)No. 33 thru 38 ... 38 N m (28 lb.ft.)b. If the bolts and nuts do not move before the correct torque is reached, back each one off 30 to 60° and retighten them again in the order shown to the torques shown in Step a. After all the bolts and nuts are retightened, check the first 10 positions again to make sure they are tightened to the correct torque.(2) Torque for nuts that hold injectors to cylinder head ... 17 N m (12 lb.ft.) Replace the copper washer and rubber seal between the head and the injector every time the injector is removed. (See Fuel Injector Installation in TESTING AND ADJUSTING.) Make sure the correct thickness washer is installed. They are as follows: 6.3544 Engines ... 2.03 mm (.080 in.)T6.3544 Engines ... 0.71 mm (.028 in.)(3) Torque for fuel line nuts ... 20 N m (15 lb.ft.)(4) Tighten rocker shaft assembly bolts and nuts from the center outward to a torque of ... 75 N m (55 lb.ft.)(5) Valve clearance (cold): Intake ... 0.20 mm (.008 in.)Exhaust ... 0.46 mm (.018 in.)(6) Maximum permissible injector nozzle projection below cylinder head face (with seating washers in position) after skimming: 6.3544 Engines ... 3.45 mm (.136 in.) max.T6.3544 Engines ... 4.67 mm (.184 in.) max.Skimming allowance ... 0.30 mm (.012 in.) max.(7) Depth of cylinder head (new) ... 94.87 to 95.63 mm (3.735 to 3.765 in.) Minimum depth of cylinder head (after skimming) ... 94.87 mm (3.735 in.)Maximum permissible amount of bow (curve of cylinder head): across width (transverse) ... 0.13 mm (.005 in.)across length (longitudinal) ... 0.25 mm (.010 in.)(See Cylinder Head Check in TESTING AND ADJUSTING)