101491-0672 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014910672 8970480482

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-0672 1014910672

ISUZU 8970480482 8970480482

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Cross reference number

ZEXEL 101491-0672 1014910672

ISUZU 8970480482 8970480482

Zexel num

Bosch num

Firm num

Name

101491-0672

8970480482 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 3.2 3.15 3.25

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 10.6

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 56.4 54.8 58

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 9.9+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 12.5 11.2 13.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.6)

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 56.4 55.4 57.4

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. 67.7 64.5 70.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 78.5 62.5 94.5

Fixing the lever *

Timer adjustment

Pump speed r/min 1425--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1375

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1750

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.
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T1=G35
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Speed control lever angle

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

----------
a=5.5deg+-5deg b=34.5deg+-3deg

Stop lever angle

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

----------
a=45deg+-5deg b=29deg+-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.
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N1=1050r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
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Ra=R1(10.6)mm Rb=R1-0.45mm Pa=95.4+-5.3kPa(716+-40mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=56.4+-1cm3/1000st Q2=(43)+-1.6cm3/1000st

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=17deg
----------
a=(90deg)

Information:

(1) Endplay for shaft (new) ... 0.102 0.025 mm (.004 .001 in) Maximum permissible endplay (worn) ... 0.20 mm (.008 in)(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.36 0.03 mm (.211 .001 in)(3) Diameter of shaft (new) ... 12.697 to 12.705 mm (.4999 to .5002 in) Bore in the bearing (new) ... 12.741 to 12.748 mm (.5016 to .5019 in)Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002 in)(4) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.25 mm (.010 in)
The impeller shaft nut is a left hand thread (CCW).
(5) Install the compressor wheel (at room temperature) as follows: a. Put compressor wheel on the shaft.b. Put a small amount of clean engine oil on the threads.c. Tighten the nut (CCW) to 14 to 17 N m (125 to 150 lb in).d. Loosen the nut and tighten again to 9 N m (80 lb in) plus an additional 60 degrees (1/6 turn).
Do not bend or add stress to the shaft when the nut is loosened or tightened.
(6) Thickness of each thrust ring ... 2.553 0.013 mm (.1005 .0005 in)(7) Bore in housing (new) ... 20.744 to 20.757 mm (.8167 to .8172 in) Outside diameter of the bearing (new) ... 20.630 to 20.643 mm (.8122 to .8127 in)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to exhaust manifold ... 55 5 N m (40 4 lb ft)Install the band clamps to hold the cartridge to the compressor housing as follows: a. Tighten clamps to 14 1.1 N m (125 10 lb in)b. Tap (hit) clamp lightly all around.c. Tighten again to ... 14 1.1 N m (125 10 lb in) Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation to provide start up lubrication and/or storage protection.