104740-1250 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401250 8944192650

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1250 1047401250

ISUZU 8944192650 8944192650

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Cross reference number

ZEXEL 104740-1250 1047401250

ISUZU 8944192650 8944192650

Zexel num

Bosch num

Firm num

Name

104740-1250
104740-1251

8944192650 ISUZU

INJECTION-PUMP ASSEMBLY
4FC1J *

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 60 58.7 61.3

Boost pressure mmHg 450 440 460

Average injection quantity mm3/st. 51.1 50.6 51.6

Difference in delivery mm3/st. 4

Basic *

Injection timing adjustment_02

Pump speed r/min 750 750 750

Boost pressure kPa 24 22.7 25.3

Boost pressure mmHg 180 170 190

Average injection quantity mm3/st. 42.1 41.6 42.6

Difference in delivery mm3/st. 5

Basic *

Injection timing 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. 17.6 16.1 19.1

Injection timing adjustment_04

Pump speed r/min 2250 2250 2250

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Average injection quantity mm3/st. 41.6 38.6 44.6

Injection timing adjustment_05

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. 43.2 40.7 45.7

Injection timing adjustment_06

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. 51.1 50.1 52.1

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. 36.4 33.9 38.9

Injection timing adjustment_08

Pump speed r/min 750 750 750

Boost pressure kPa 24 22.7 25.3

Boost pressure mmHg 180 170 190

Average injection quantity mm3/st. 42.1 41.1 43.1

Injection timing adjustment_09

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 38.2 35.7 40.7

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. 17.6 16.6 18.6

Difference in delivery mm3/st. 5.5

Basic *

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

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 *

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

Governor adjustment_03

Pump speed r/min 575 575 575

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. 77.5 60 95

Basic *

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

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 400 270 530

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Pressure kPa 441.5 422 461

Pressure kgf/cm2 4.5 4.3 4.7

Basic *

Stop lever angle_02

Pump speed r/min 600 600 600

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Pressure kPa 255 226 284

Pressure kgf/cm2 2.6 2.3 2.9

Stop lever angle_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Pressure kPa 441.5 422 461

Pressure kgf/cm2 4.5 4.3 4.7

Stop lever angle_04

Pump speed r/min 1750 1750 1750

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Pressure kPa 578.5 549 608

Pressure kgf/cm2 5.9 5.6 6.2

Stop lever angle_05

Pump speed r/min 2250 2250 2250

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Pressure kPa 730.5 686 775

Pressure kgf/cm2 7.45 7 7.9

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Timer stroke mm 2.6 2.4 2.8

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Timer stroke mm 2.6 2.3 2.9

_03

Pump speed r/min 1750 1750 1750

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Timer stroke mm 5.2 4.6 5.8

_04

Pump speed r/min 2250 2250 2250

Boost pressure kPa 60 58.7 61.3

Boost pressure mmHg 450 440 460

Timer stroke mm 7.8 7.4 8.2

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 60 58.7 61.3

Boost pressure mmHg 450 440 460

Average injection quantity mm3/st. 30 29 31

Timer stroke variation dT mm 1 0.8 1.2

Basic *

_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. 30 28.5 31.5

Timer stroke variation dT mm 1 0.7 1.3

_03

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. 23 21.5 24.5

Timer stroke variation dT mm 1.6 1.1 2.1

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 4.2 4.1 4.3

Control lever angle alpha deg. 24.5 20.5 28.5

Control lever angle beta deg. 40.5 35.5 45.5

Test data Ex:

0000001801 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the timer stroke Adjust using screw (A) so that the timer stroke is the value determined using the graph (M). [(K), (M)] 2. Adjustment of the position of the intermediate lever. Insert a shim (J) L1 between the control lever (I) and the FICD screw (E). Insert a shim L2 between the control lever (I) and the idle set screw (G). Align the intermediate lever (F) with the aligning line. Fix the screw (E) so that it contacts the control lever (F). [(K), (L)] 3. Adjustment of the FICD With the shim (J) inserted, insert a shim L3 between the control lever (I) 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 (F) via the rod (D). [(K), (L), (M)] (O) = timer stroke adjustment (mm) - (1): TA = -0.0215t+0.75 (P) = lever angle (deg) - (2): theta = -0.1925t + 7.71 (Q) = Lever position (mm): L = -0.0635t+2.52 The (Q) indicates the clearance between the control lever and the idle set screw. (R) = cooling water temperature (deg C) (S) = cooling water temperature: increase direction N = pump speed X = temperature t (deg C) Y1 = timer stroke TA (mm) Y2 = control lever angle theta, L (deg mm) (K) = Figure 1 (L) = Figure 2 (M) = Figure 3 (T) = Timer piston stroke (mm) (U) = Lever angle (deg) (W) = Lever position (mm)
----------
L1=1.9+-0.05mm L2=1.25+-0.05mm L3=L2+-0.05mm
----------
N1=100r/min a=20degC b=-20degC c=3.9+-1deg d=(11.6+-3)deg T1=0.3+0.4-0.2mm T2=1.2+0.6-0.4mm W1=1.3+-0.3mm W2=(3.8+-1)mm

Information:

REMOVING CONNECTING ROD BEARING CAP4. Push the piston and connecting rod upward until the piston rings clear the cylinder block. Remove the piston and connecting rod from the cylinder block.
REMOVING PISTON
Do not allow the connecting rods to hit the bottom edge of the cylinder bores or crankshaft journals when removing or installing. Check the lower portion of the bores for burrs or scratches. Use crocus cloth to remove any burrs or scratches from bottom edge of the bores.
5. Keep the connecting rod bearing cap with its respective connecting rod and piston.6. Repeat Steps 2 through 5 for the remaining pistons.Install Pistons
1. Rotate the crankshaft to position bearing journal of the piston to be installed.2. Lubricate the crankshaft bearing journal, bore in cylinder block, piston, rings, and connecting rod bearings with clean engine oil (SAE 30).3. Install a 1Y7426 Ring Compressor (3), or the 4S9450 Compressor (1) and the 4S9446 Clamp (2) from the 4S9458 Teflon Seal Tool Group, on the piston to compress the rings. Install the piston and connecting rod in cylinder bore with piston crater toward vee of engine. Guide the lower end of connecting rod over the crankshaft journal to prevent damage to the crankshaft.
INSTALLING PISTON
1. 4S9450 Compressor. 2. 4S9446 Clamp.
INSTALLING PISTON ALTERNATE METHOD
3. 1Y7426 Ring Compressor.4. Install the connecting rod cap to connecting rod so numbers correspond and both numbers appear on the same side. Lubricate bolt threads, seating faces of cap and nuts, install the retaining nuts and tighten to 30 3 lb. ft. (4.1 0.4 mkg). Mark cap and nut with matching marks. Tighten additional from mark 60° 5°.5. Repeat Steps 1 thru 4 for the remaining pistons.Disassemble Piston
PISTON ASSEMBLY1. Use ring expander (1) to remove rings.
REMOVING RINGS
1. 5F9059 Ring Expander.2. Remove snap ring (5) and push piston pin (2) out of piston (4) and connecting rod (3).
PISTON DISASSEMBLED
2. Piston pin. 3. Connecting rod. 4. Piston. 5. Snap ring.Assemble Piston
1. Install connecting rod into piston with boss on rod on same side as crater in piston crown.
CONNECTING ROD AND PISTON
CONNECTING ROD AND PISTON Installation of connecting rods WITHOUT BOSS on rod; Install connecting rod into piston with cylinder identification number (as marked on the lower end of the rod and on the cap) 180° opposite the crater in piston crown.2. Install piston pin and snap rings.3. Use the 8S2304 Piston Ring Groove Cleaner to clean the piston ring grooves before installing piston rings.4. Install oil ring spring (6) before installing oil ring.
8S2304 RING GROOVE CLEANER
INSTALLING OIL RING SPRING
6. Oil ring spring.5. Use a 5F9059 Ring Expander to install piston rings. Install compression ring with side marked "TOP" toward top of piston. Install oil ring with gap 180° from oil ring spring joint and approximately 120° from compression ring gap.