104740-1080 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401080 8941220661

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1080 1047401080

ISUZU 8941220661 8941220661

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Cross reference number

ZEXEL 104740-1080 1047401080

ISUZU 8941220661 8941220661

Zexel num

Bosch num

Firm num

Name

104740-1080
104740-1081

8941220661 ISUZU

INJECTION-PUMP ASSEMBLY
4FC1 *

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105000-2010

Bosch type code NP-DN12SD12TT

Nozzle holder 105780-2080

Opening pressure MPa 14.7 14.7 15.19

Opening pressure kgf/cm2 150 150 155

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840

Transfer pump pressure kPa 20 20 20

Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Pump speed r/min 1250 1250 1250

Boost pressure kPa 65.35 64 66.7

Boost pressure mmHg 490 480 500

Average injection quantity mm3/st. 46.3 45.8 46.8

Difference in delivery mm3/st. 4

Basic *

Injection timing adjustment_02

Pump speed r/min 2600 2600 2600

Boost pressure kPa 65.35 64 66.7

Boost pressure mmHg 490 480 500

Average injection quantity mm3/st. 15.6 14.1 17.1

Injection timing adjustment_03

Pump speed r/min 2250 2250 2250

Boost pressure kPa 65.35 64 66.7

Boost pressure mmHg 490 480 500

Average injection quantity mm3/st. 37.3 34.8 39.8

Injection timing adjustment_04

Pump speed r/min 2000 2000 2000

Boost pressure kPa 65.35 64 66.7

Boost pressure mmHg 490 480 500

Average injection quantity mm3/st. 40.25 37.7 42.8

Injection timing adjustment_05

Pump speed r/min 1250 1250 1250

Boost pressure kPa 65.35 64 66.7

Boost pressure mmHg 490 480 500

Average injection quantity mm3/st. 46.3 45.3 47.3

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 30.8 28.3 33.3

Injection timing adjustment_07

Pump speed r/min 900 900 900

Boost pressure kPa 45.35 44 46.7

Boost pressure mmHg 340 330 350

Average injection quantity mm3/st. 44.3 43.3 45.3

Injection timing adjustment_08

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 29.15 26.6 31.7

Injection quantity adjustment

Pump speed r/min 2600 2600 2600

Boost pressure kPa 65.35 64 66.7

Boost pressure mmHg 490 480 500

Average injection quantity mm3/st. 15.6 14.6 16.6

Difference in delivery mm3/st. 3

Basic *

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Boost pressure kPa 65.35 64 66.7

Boost pressure mmHg 490 480 500

Average injection quantity mm3/st. 5

Governor adjustment

Pump speed r/min 330 330 330

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 9.7 7.7 11.7

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 330 330 330

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 9.7 7.7 11.7

Governor adjustment_03

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 60 50 70

Basic *

Speed control lever angle

Pump speed r/min 330 330 330

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 399 270 528

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure kPa 470.5 451 490

Pressure kgf/cm2 4.8 4.6 5

Basic *

Stop lever angle_02

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure kPa 313.5 284 343

Pressure kgf/cm2 3.2 2.9 3.5

Stop lever angle_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure kPa 470.5 451 490

Pressure kgf/cm2 4.8 4.6 5

Stop lever angle_04

Pump speed r/min 2100 2100 2100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure kPa 676.5 647 706

Pressure kgf/cm2 6.9 6.6 7.2

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 3.2 3 3.4

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 3.2 2.9 3.5

_03

Pump speed r/min 2100 2100 2100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 7.4 7 7.8

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 1.2 1.1 1.3

BCS stroke mm 4.9 4.7 5.1

Pre-stroke mm 0 0 0

Control lever angle alpha deg. -20.5 -24.5 -16.5

Control lever angle beta deg. 43 38 48

Information:

(1) End play for the crankshaft ... .006 .003 in.(0.15 0.08 mm) Maximum permissible end play for the crankshaft (worn) ... .012 in.(0.30 mm)(2) Diameter of bearing surfaces (journals) for the connecting rods [standard, original size] ... 2.7500 .0004 in.(69.850 0.010 mm) Minimum permissible diameter (worn) ... 2.7486 in.(69.814 mm)Diameter of bearing surfaces (journals) for the connecting rods [.010 in. (0.25 mm) smaller than the original size] ... 2.7400 .0004 in.(69.596 0.010 mm)Minimum permissible diameter (worn) ... 2.7386 in.(69.560 mm)Diameter of bearing surfaces (journals) for the connecting rods [.020 in. (0.51 mm) smaller than the original size] ... 2.7300 .0004 in.(69.342 0.010 mm)Minimum permissible diameter (worn) ... 2.7286 in.(69.306 mm)(3) Diameter of bearing surfaces (journals) for the main bearings [standard, original size] ... 3.5000 .0005 in.(88.900 0.013 mm) Minimum permissible diameter (worn) ... 3.4985 in.(88.862 mm)Diameter of bearing surfaces (journals) for the main bearings [.010 in. (0.25 mm) smaller than the original size] ... 3.4900 .0005 in.(88.646 0.013 mm)Minimum permissible diameter (worn) ... 3.4885 in.(88.608 mm)Diameter of bearing surfaces (journals) for the main bearings [.020 in. (0.51 mm) smaller than the original size] ... 3.4800 .0005 in.(88.392 0.013 mm)Minimum permissible diameter (worn) ... 3.4785 in.(88.354 mm)Bore in main bearing ... 3.5030 .0010 in.(88.976 0.025 mm)Clearance between main-bearing and crankshaft bearing surface (journal) ... .0015 to .0045 in.(0.038 to 0.114 mm)Maximum permissible clearance between main bearing and crankshaft bearing surface (journal) ... .006 in.(0.15 mm)Maximum permissible run out (axial eccentricity) of the crankshaft, measured at the center main bearing surface (journal) ... .006 in.(0.15 mm)Maximum permissible run out (axial eccentricity) of the crankshaft, measured at No.2 and No.4 main bearing surfaces (journal) ... .003 in.(0.08 mm)(9L8122, 9L8123, 9L8400)
Before installing gear, get temperature of gear to a maximum of 300° F (149° C)(1) End play for the crankshaft ... .006 .003 in.(0.15 0.08 mm) Maximum permissible end play for the crankshaft (worn) ... .012 in.(0.30 mm)(2) Diameter of bearing surfaces (journals) for the connecting rods ... 2.7500 .0004 in.(69.850 0.010 mm) Minimum permissible diameter (worn) ... 2.7486 in.(69.814 mm)(3) Diameter of bearing surfaces (journals) for main bearings ... 3.5000 .0005 in.(88.900 0.013 mm) Minimum permissible diameter (worn) ... 3.4985 in.(88.862 mm)Bore in main bearing ... 3.5030 .0010 in.(88.976 0.025 mm)Clearance between main bearing and crankshaft bearing surface (journal) ... .0015 to .0045 in.(0.038 to 0.114 mm)Maximum permissible clearance between main bearing and crankshaft bearing surface (journal) ... .006 in.(0.15 mm)Maximum permissible run out (axial eccentricity) of the crankshaft, measured at the center bearing surface (journal): 4.1 in. (104.1 mm) stroke engine ... .006 in.(0.15 mm)4.5 in. (114.3 mm) stroke engine ... .007 in.(0.18 mm)5.0 in. (127.0 mm) stroke engine ... .008 in.(0.20 mm)