101491-0060 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014910060 5156013220

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101491-0060 1014910060

ISUZU 5156013220 5156013220

Service parts 101491-0060 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8150

3. GOVERNOR 105931-0860

4. SUPPLY PUMP 105220-5060

5. AUTOM. ADVANCE MECHANIS 105622-0861

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5120

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3700

14. NOZZLE

105015-4740

15. NOZZLE SET

Include in #1:

101491-0060 as INJECTION-PUMP ASSEMBLY

106672-9581 as _

Cross reference number

ZEXEL 101491-0060 1014910060

ISUZU 5156013220 5156013220

Zexel num

Bosch num

Firm num

Name

101491-0060

5156013220 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

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 10.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 51 49.4 52.6

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 9.8+-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. 51 50 52

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. 49.2 47.6 50.8

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. 40 38.4 41.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 42.1 40.1 44.1

Fixing the lever *

Timer adjustment

Pump speed r/min 1650--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 0.6

Timer adjustment_03

Pump speed r/min 1800

Advance angle deg. 3 2.5 3.5

Timer adjustment_04

Pump speed r/min 1900

Advance angle deg. 4.5 4 5

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 5 5 5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1
----------
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=45deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 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)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=1100r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(10.2)mm Rb=R1-0.6mm Pa=4+-2.7kPa(30+-20mmHg) Pb=22kPa(165mmHg) Q1=51+-1cm3/1000st Q2=-

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=(100deg)