104740-1190 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401190 8941782080

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1190 1047401190

ISUZU 8941782080 8941782080

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Cross reference number

ZEXEL 104740-1190 1047401190

ISUZU 8941782080 8941782080

Zexel num

Bosch num

Firm num

Name

104740-1190

8941782080 ISUZU

INJECTION-PUMP ASSEMBLY
4FC1-J *

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 900 900 900

Boost pressure kPa 37.3 36 38.6

Boost pressure mmHg 280 270 290

Average injection quantity mm3/st. 47.5 47 48

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Average injection quantity mm3/st. 51.3 50.8 51.8

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 37.4 35.4 39.4

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 900 900 900

Boost pressure kPa 37.3 36 38.6

Boost pressure mmHg 280 270 290

Average injection quantity mm3/st. 47.5 46.5 48.5

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1250 1250 1250

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Average injection quantity mm3/st. 51.3 50.3 52.3

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

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. 39.7 37.7 41.7

Difference in delivery mm3/st. 3.5

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 2150 2150 2150

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Average injection quantity mm3/st. 45.7 43.7 47.7

Difference in delivery mm3/st. 5.5

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2600 2600 2600

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Average injection quantity mm3/st. 17.5 16.5 18.5

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2600 2600 2600

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Average injection quantity mm3/st. 17.5 14.5 20.5

Difference in delivery mm3/st. 5.5

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12.2 10.2 14.2

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12.2 10.2 14.2

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

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 60

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

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 60

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 400 270 530

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure kPa 441 421 461

Pressure kgf/cm2 4.5 4.3 4.7

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure kPa 441 412 470

Pressure kgf/cm2 4.5 4.2 4.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1750 1750 1750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure kPa 598 569 627

Pressure kgf/cm2 6.1 5.8 6.4

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 2.6 2.4 2.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 840 740 940

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 0.5 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 2.6 2.4 2.8

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1750 1750 1750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 5.2 4.8 5.6

Oil temperature degC 50 48 52

_05

Pump speed r/min 2250 2250 2250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 7.8 7.5 8.2

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

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 29 31

Timer stroke TA mm 1.6 1.6 1.6

Timer stroke variation dT mm 1 0.8 1.2

Basic *

Oil temperature degC 50 48 52

_02

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 29 31

Timer stroke variation dT mm 1 0.6 1.4

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 25 24 26

Timer stroke variation dT mm 1.55 1.15 1.95

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 1.3 1.2 1.4

BCS stroke mm 3.5 3.3 3.7

Control lever angle alpha deg. 23 19 27

Control lever angle beta deg. 45 40 50

Test data Ex:

0000001801 MICROSWITCH ADJUSTMENT

Microswitch adjustment With the control lever 'a' from the idle position (idle stopper lever clearance L), adjust the position of the microswitch and fix it in the position where it goes OFF. After adjustment, the microswitch must not turn OFF at lever position between idle and a. Also, the microswitch lever must not contact the stopper.
----------
a=26+-1deg L=8.5+-0.2mm
----------

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the timer stroke Adjust screw (A) so that the timer stroke is the value determined from the graph. 2. Adjustment of the position of the intermediate lever. (1)Insert a shim L1 between the control lever (F) and the idle set screw (G). (2)Set intermediate lever (D) adjusting screw (E) so that adjusting screw (E) contacts control lever, and so that when intermediate lever is at right angles to pump center, intermediate lever and idle stopper bracket (H) overlap at position (J). 3. W-CSD adjustment Insert a shim L1+-0.05 between the control lever (F) and the idle set screw (G). Use adjusting screw (B) to fix the CSD lever (C) in the position where it operates the intermediate lever (D) via the rod (I). X:Temperature t (deg C) Y1:Timer stroke TA (mm) Y2:Control lever position at theta L (deg, mm) (W) Cold advancer (R) Cooling water temperature (deg C) (S) Cooling water temperature: increase direction (O) Timer piston stroke (mm) (P) Lever position (deg) (Q) lever position (mm) (M) standard point N:Pump speed
----------
L1=0.93+-0.05mm
----------
N1=500r/min a=20degC b=-20degC c=2.9+-1deg d=8+-3deg O1=0.3+-0.4mm O2=1.2+-0.6mm Q1=0.93+-0.3mm Q2=2.62+-1mm

Information:

TIMING PIN HOLE PLUG (Typical Example)
1. Plug.2. Rotate the crankshaft CLOCKWISE (as viewed from front of engine) until the timing pin drops into the timing slot in the fuel injection pump camshaft.3. Disconnect wire (2) from fuel shut off solenoid.4. Remove the tachometer drive adapter housing (3).
WIRE AND HOUSING (Typical Example)
2. Wire. 3. Tachometer drive adapter housing.5. Use ratchet (4) and socket (5) to remove the tachometer drive adapter shaft.
REMOVING SHAFT
4. 8H8572 Ratchet. 5. 9S5031 Deep Well Socket.6. Using puller group (6), thread the 9S8528 Bolt Assembly into the camshaft. Do not force the bolt assembly. It should thread easily. Install the 9S8527 Bolt by threading it into the gear carrier or adapter. Then tighten the 9S8527 Bolt with a wrench until the gear carrier or adapter "pops" loose. Remove the 9S8520 Puller Group.
LOOSENING CAMSHAFT DRIVE GEAR
6. 9S8520 Puller Group.7. Remove the plug from the timing hole (8) in the front cover and insert bolt (7). The cover retaining bolt from hole (9) may be used.8. Rotate crankshaft CLOCKWISE (as viewed from front of engine) until bolt (7) threads into the timing gear and is centered in timing hole (8). With timing pin in slot in fuel pump camshaft and the bolt (7) through the front cover and threaded into the timing gear, the fuel injection pump camshaft is timed to the engine.
INSTALLING BOLT
7. 1D4539 Bolt [5/16 in. - 18 NC, 2.5 in. (63.5 mm) long]. 8. Timing hole. 9. Hole.9. Remove the fuel injection pump housing retaining bolts (10).
RETAINING BOLTS (Typical Example)
10. Retaining bolts (three).
REMOVING HOUSING (Typical Example)10. Attach a hoist and remove the fuel injection pump housing and governor as a unit, the weight is approx. 55 lbs. (23 kg).Install Fuel Injection Pump Housing and Governor
1. Attach a hoist and install the fuel injection pump housing and governor as a unit. Install the fuel injection pump housing retaining bolts.2. Install the tachometer drive adapter shaft and tighten shaft retaining nut to 32 2 lb. ft. (4.4 0.3 mkg).3. To check timing remove the timing pin and the bolt. Rotate the crankshaft two revolutions CLOCKWISE (as viewed from front of engine) and install the timing pin and bolt back in place. If the timing pin or bolt can not be installed, the fuel injection pump camshaft must be retimed.4. Remove the bolt (7) from the timing gear and install in hole (9). Install the plug into timing hole (8).5. Remove the timing pin from the timing slot in the fuel injection pump camshaft and install the plug in the timing hole.6. Install the tachometer drive adapter housing. Connect the wire to the fuel shut off solenoid.