101491-0544 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014910544 8970318680


101491-0544 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101491-0544 1014910544
ISUZU 8970318680 8970318680

Service parts 101491-0544 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101049-8720
3. GOVERNOR 105931-8050
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:

101491-0544 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101491-0544 1014910544
ISUZU 8970318680 8970318680


Zexel num
Bosch num
Firm num
Name
101491-0544 
101491-0545 
 
8970318680  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 -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   9.5+-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 101491-0544
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 101491-0544
F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)Set the idle side stopper bolt at speed = aa and rack position = bb (at delivery)
----------
aa=100r/min bb=R1(12.2)mm
----------
a=(8deg) b=(33deg)+-3deg c=4deg+-5deg

Stop lever angle

Test data 101491-0544
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 101491-0544
(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=(90deg)




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