101491-0300 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014910300 8944041060

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101491-0300 1014910300

ISUZU 8944041060 8944041060

Service parts 101491-0300 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8330

3. GOVERNOR 105931-3420

4. SUPPLY PUMP 105210-4610

5. AUTOM. ADVANCE MECHANIS 105622-1260

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6391

11. Nozzle and Holder 8-94151-865-1

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-6060

15. NOZZLE SET

Include in #1:

101491-0300 as INJECTION-PUMP ASSEMBLY

101492-3220 as _

Cross reference number

ZEXEL 101491-0300 1014910300

ISUZU 8944041060 8944041060

Zexel num

Bosch num

Firm num

Name

101491-0300
101491-0303

8944041060 ISUZU

INJECTION-PUMP ASSEMBLY
4BC2 *

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. 55.4 53.8 57

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

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 -10 10

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. 55.4 54.4 56.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 53 49.8 56.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.15

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 44.4 41.2 47.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 42.2 38.2 46.2

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 (2)The torque cam setting and high idle must be set when speed is increasing from low to high (because of hysterisis).
----------
T1=B22
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)Adjust the lever position using the bolt so that when the microswitch is ON, speed = aa and rack position = bb. (3)After microswitch installation, confirm that the speed lever moves smoothly and that the full speed lever angle = beta.
----------
aa=1150r/min bb=8.1mm
----------
a=0deg+-5deg b=(51deg)+-3deg c=(23.5deg)+-3deg

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)