104740-1421 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401421 8944542981

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1421 1047401421

ISUZU 8944542981 8944542981

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Cross reference number

ZEXEL 104740-1421 1047401421

ISUZU 8944542981 8944542981

Zexel num

Bosch num

Firm num

Name

104740-1421
104740-1423

8944542981 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 26.7 25.4 28

Boost pressure mmHg 200 190 210

Average injection quantity mm3/st. 43.5 43 44

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 47.8 47.3 48.3

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 900 900 900

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Average injection quantity mm3/st. 43.5 42.5 44.5

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1250 1250 1250

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 47.8 46.8 48.8

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 2175 2175 2175

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 42.9 40.9 44.9

Oil temperature degC 52 50 54

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. 41.4 39.4 43.4

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2550 2550 2550

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 22.8 19.8 25.8

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 55 53 57

Injection quantity adjustment_02

Pump speed r/min 2550 2550 2550

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 22.8 19.8 25.8

Difference in delivery mm3/st. 7

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2800 2800 2800

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 7

Oil temperature degC 55 53 57

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 *

Oil temperature degC 48 46 50

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

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 375 375 375

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 471 451 491

Pressure kgf/cm2 4.8 4.6 5

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 471 451 491

Pressure kgf/cm2 4.8 4.6 5

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 2175 2175 2175

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure kPa 686 657 715

Pressure kgf/cm2 7 6.7 7.3

Oil temperature degC 52 50 54

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 *

Oil temperature degC 50 48 52

_02

Pump speed r/min 860 760 960

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 3.4 3.2 3.6

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 6.8 6.5 7.1

Oil temperature degC 50 48 52

_05

Pump speed r/min 2175 2175 2175

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 9 8.7 9.4

Oil temperature degC 52 50 54

_06

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

Oil temperature degC 48 46 50

Remarks
C.S.D. advance angle

_07

Pump speed r/min 600 500 700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Oil temperature degC 50 48 52

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 1.4 1.3 1.5

BCS stroke mm 1.8 1.6 2

Control lever angle alpha deg. 17 13 21

Control lever angle beta deg. 42 37 47

Test data Ex:

0000001801 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Adjust the actuator rod to obtain L1. 2. Apply negative pressure P1 {P2} to the actuator and confirm that it moves through its full stroke. (A) actuator shaft (B) Control lever
----------
L=1+1mm P1=-53.3kPa P2=-400mmHg
----------
L=1+1mm

0000001901 POTENTIOMETER ADJUSTMENT

Potentiometer adjustment (oval) N:Pump speed Vo:Output voltage Q:Injection quantity A:Adjusting point B:Target value Vi:Applied voltage
----------

----------
N1=700(r/min) N2=500(r/min) V1=4.10(V) V2=3.33(V) Q1=22.9+-1(mm3/st) Q2=(18.6(mm3/st)) Vi=10(V)

Information:

1. Disconnect the fuel ratio control sensing line (1). Remove the sensing line clamp bolt (2).2. Disconnect the air compressor water return line (6). 3. Remove the cylinder head air inlet line (3).4. Remove the retaining bolts (4) and the fan drive mounting bracket (5).5. Remove the cylinder head retaining bolts. Attach a hoist and remove the cylinder head assembly - weight 164 lbs. (74,4 kg).Install Cylinder Head
1. Thoroughly clean the sealing surfaces of the cylinder head and cylinder block. Position a new head gasket on the engine and install the cylinder head.2. Install the push rods and rocker shaft assembly.3. Coat the threads of the cylinder head retaining bolts with 4S9416 Anti-Seize Compound. Install bolts and washers, and tighten them in the following sequence: 1 - Tighten all numbered bolts in numerical order to 115 lb. ft. (15,9 mkg).2 - Retighten all numbered bolts in numerical order to 175 5 lb. ft. (24,2 0,7 mkg).3 - Finally, retighten all numbered bolts (hand torque only) in numerical order to 175 5 lb. ft. (24,2 0,7 mkg).4 - Tighten all lettered bolts in alphabetical order to 22 lb. ft. (3,0 mkg).5 - Retighten all lettered bolts in alphabetical order to 32 5 lb. ft. (4,4 0,7 mkg).6 - Finally, retighten all lettered bolts (hand torque only) in alphabetical order to 32 5 lb. ft. (4,4 0,7 mkg).4. Adjust the inlet and exhaust valve clearance as covered in INSTALL ROCKER SHAFT ASSEMBLY AND PUSH RODS.5. Connect the air compressor water return line.6. Connect the fuel ratio control sensing line and install the sensing line clamp bolt.7. Install the fan drive mounting bracket and retaining bolts.concluding steps: a) install water temperature regulatorb) install valve coverc) install precombustion chambersd) install exhaust manifold