104740-1412 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401412 8944542972

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1412 1047401412

ISUZU 8944542972 8944542972

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Cross reference number

ZEXEL 104740-1412 1047401412

ISUZU 8944542972 8944542972

Zexel num

Bosch num

Firm num

Name

104740-1412
104740-1413

8944542972 ISUZU

INJECTION-PUMP ASSEMBLY
C223T *

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 33.35 32 34.7

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 43.8 43.3 44.3

Difference in delivery mm3/st. 3.5

Basic *

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 79.95 78.6 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 46.9 46.4 47.4

Difference in delivery mm3/st. 4

Basic *

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 2550 2550 2550

Boost pressure kPa 79.95 78.6 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 22.9 19.4 26.4

Injection timing adjustment_04

Pump speed r/min 2300 2300 2300

Boost pressure kPa 79.95 78.6 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 34 30.5 37.5

Injection timing adjustment_05

Pump speed r/min 2150 2150 2150

Boost pressure kPa 79.95 78.6 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 40 36.5 43.5

Injection timing adjustment_06

Pump speed r/min 2000 2000 2000

Boost pressure kPa 79.95 78.6 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 42.8 40.3 45.3

Injection timing adjustment_07

Pump speed r/min 1250 1250 1250

Boost pressure kPa 79.95 78.6 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 46.9 45.9 47.9

Injection timing adjustment_08

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 40.6 38.1 43.1

Injection timing adjustment_09

Pump speed r/min 1150 1150 1150

Boost pressure kPa 79.95 78.6 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 47.8 45.3 50.3

Injection timing adjustment_10

Pump speed r/min 900 900 900

Boost pressure kPa 33.35 32 34.7

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 43.8 42.8 44.8

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 79.95 78.6 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 34 31 37

Basic *

Injection quantity adjustment_02

Pump speed r/min 2900 2900 2900

Boost pressure kPa 79.95 78.6 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 7

Governor adjustment

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 11.3 9.3 13.3

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 11.3 9.3 13.3

Governor adjustment_03

Pump speed r/min 600 600 600

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 60

Basic *

Speed control lever angle

Pump speed r/min 375 375 375

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 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_03

Pump speed r/min 2000 2000 2000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure kPa 637.5 608 667

Pressure kgf/cm2 6.5 6.2 6.8

Stop lever angle_04

Pump speed r/min 2150 2150 2150

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 3.4 3.2 3.6

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 3.4 3.1 3.7

_03

Pump speed r/min 1700 1700 1700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 6.8 6.2 7.4

_04

Pump speed r/min 2000 2000 2000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 9 8.6 9.4

_05

Pump speed r/min 2150 2150 2150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 9 8.6 9.4

_06

Pump speed r/min 600 500 700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
C.D.. cancel speed.

_07

Pump speed r/min 0 0 0

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 2.5 2.3 2.7

_08

Pump speed r/min 600 500 700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
C.D.. cancel speed.

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 1.3 1.2 1.4

BCS stroke mm 1.9 1.8 2

Control lever angle alpha deg. 17 13 21

Control lever angle beta deg. 42 37 47

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjusting method N = pump speed V = output voltage Q = injection quantity P = boost pressure A = adjusting point B = target value Vi = applied voltage
----------

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N1=700r/min N2=500r/min N3=-r/min V1=4.10V V2=3.33V V3=-V Q1=25.4+-1cm3/1,000st Q2=22.7cm3/1,000st Q3=-cm3/1,000st P1=80.0kPa P2=600mmHg

Information:

preparatory step: a) remove air compressor1. Disconnect the water pump outlet line (1).2. Disconnect the water temperature regulator water bypass line (2).3. Remove the water pump (3).Install Water Pump
1. Position the water pump on the engine.2. Connect the water temperature regulator bypass line.3. Connect water pump outlet line.concluding step: a) install air compressorDisassemble Water Pump
preparatory step: a) remove water pump 1. Remove the water pump cover (1). 2. Loosen the impeller retaining nut flush with the end of the pump shaft. Install tool setup (A) and separate the impeller from the shaft.3. Remove the tool setup and impeller. 4. Remove the bearing cage retaining nuts (3).5. Remove the bearing cage and shaft assembly (2) from the pump housing.6. Remove the ceramic seal and oil seal from the pump housing.7. Remove the bearing retaining nut and spacer from the shaft assembly. 8. Press the gear and bearings from the shaft.Assemble Water Pump
1. Heat the bearings and gear to 300°F (149°C). 2. Install one bearing and its bearing cage (5) on the shaft. Install the gear (4) on the shaft with the concave side towards the bearing cage.3. Install the remaining bearing (3), spacer (2), lock and retaining nut (1). 4. Install the oil seal in the pump housing using tool setup (A). Install the oil seal (8) as shown. 5. Install the ceramic ring (11) and rubber seal (12) in the pump housing with the polished side of the ceramic ring toward the impeller.6. Position the bearing and shaft assembly in the pump housing. Install the bearing cage retaining nuts (7). Lubricate the oil seal lip lightly with SAE 30 engine oil before installing the shaft assembly.7. Install the carbon portion of the seal and the spring on the shaft.8. Install the impeller (10) and retaining nut (6). Tighten the nut to 30 5 lb. ft. (4,1 0,7 mkg) plus the amount required to align on cotter pin hole. Install the cotter pin and bend the legs of the pin around the nut.9. Install the water pump cover (9).concluding step: a) install water pump