Information injection-pump assembly
ZEXEL
104740-1221
1047401221
ISUZU
8944119001
8944119001
Rating:
Cross reference number
ZEXEL
104740-1221
1047401221
ISUZU
8944119001
8944119001
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
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
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
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
900
900
900
Boost pressure
kPa
45.35
44
46.7
Boost pressure
mmHg
340
330
350
Average injection quantity
mm3/st.
44.3
43.8
44.8
Injection timing adjustment_03
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_04
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_05
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_06
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_07
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_08
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_09
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
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
4.8
4.7
4.9
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:
WRENCH INSTALLED
1. 8S2243 Wrench. 2. Protective cap. 3. Retaining bushing.c. Install extractor (4).d. Remove retaining bushing (3) and wrench (1).e. Remove the seal and lift fuel injection pump (5) out of the housing. Keep components together and identified as to location.4. Remove rack (7) and rack bumper spring (6).
REMOVING PUMP
4. 8S2244 Extractor. 5. Fuel injection pump.
REMOVING RACK
6. Rack bumper spring. 7. Rack.5. Use magnet (8) to remove lifters (9). Identify lifters (9) and keep them with their respective fuel injection pumps.
REMOVING LIFTERS
8. 8S2293 Magnet. 9. Lifter.6. Remove the camshaft gear assembly retaining bolt (11) and lock. Remove plate assembly (10).
REMOVING PLATE ASSEMBLY
10. Plate assembly. 11. Bolt.7. Remove camshaft gear assembly (12) from camshaft (13).
REMOVING GEAR ASSEMBLY
12. Gear assembly. 13. Camshaft.
REMOVING BOLTS
14. Lock. 15. Bolts.8. Remove bolts (15) and lock (14).9. Remove camshaft retaining plate (16).
REMOVING RETAINING PLATE
16. Retaining plate.10. Remove camshaft (13).
REMOVING CAMSHAFT
13. Camshaft.11. Use camshaft bearing removal and installation group (17) to remove the camshaft bearings from the fuel injection pump housing.
REMOVING BEARINGS
17. 8S2241 Camshaft Bearing Removal and Installation Group.Assemble Fuel Injection Pump Housing
1. Use camshaft bearing removal and installation group (17) to install the camshaft bearings in the fuel injection pump housing. The camshaft bearings must be installed with the oil holes in the bearings in line with the oil hole in the housing. The front and rear bearings must be line bored after installation. To align oil holes and line bore the bearings, See Special Instruction (GMG00672).
INSTALLING BEARINGS
17. 8S2241 Camshaft Bearing Removal and Installation Group.2. Put clean engine oil (SAE 30) on the camshaft and install camshaft (13) in the fuel injection pump housing.
INSTALLING CAMSHAFT
13. Camshaft.3. Install the camshaft retaining plate (16).4. Install lock (14) and bolts (15).
INSTALLING RETAINING PLATE
16. Retaining plate.
INSTALLING BOLTS
14. Lock. 15. Bolts.5. Install camshaft gear assembly (12) on camshaft (13).
INSTALLING GEAR ASSEMBLY
12. Gear assembly. 13. Camshaft.6. Install plate assembly (10), retaining bolt (11), and lock.
INSTALLING PLATE ASSEMBLY
10. Plate assembly. 11. Bolt. Be sure to put the spacer on bolt (11).7. Use magnet (8) to install lifters (9). The lifters (9) must be installed in the same location from which they were removed.
INSTALLING LIFTERS
8. 8S2293 Magnet. 9. Lifters.8. Lubricate the rack with clean fuel oil. Install rack (7) with timing pin slot in rack toward front of the housing. Install rack bumper spring (6) so the large diameter of the bumper spring will be against the housing. If new lifters and pumps are to be installed it will be necessary to check and/or adjust the fuel pump timing dimension. See FUEL PUMP TIMING DIMENSION SETTING-OFF ENGINE in TESTING AND ADJUSTING section of the Service Manual.
INSTALLING RACK
6. Rack bumper spring. 7. Rack.9. Remove bolts (19) and rack cover (18).
RACK COVER
18. Rack cover. 19. Bolts.
TIMING PIN INSTALLED
20. Slot in rack. 21. 8S2291 or FT887 Timing Pin.10. The rack must be centered to install the fuel injection pumps. To center the rack, pull the rack toward the governor end of the housing until centering slot (20) in the rack is under the centering pin hole.