104740-1460 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401460 8944648560

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1460 1047401460

ISUZU 8944648560 8944648560

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Cross reference number

ZEXEL 104740-1460 1047401460

ISUZU 8944648560 8944648560

Zexel num

Bosch num

Firm num

Name

104740-1460
104740-1571

8944648560 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 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 46.3 45.8 46.8

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. 48.3 47.8 48.8

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 2175 2175 2175

Boost pressure kPa 79.95 78.6 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 39.1 36.6 41.6

Injection timing adjustment_05

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. 48.3 47.3 49.3

Remarks
Full

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. 37.3 34.8 39.8

Injection timing adjustment_07

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. 49.3 46.8 51.8

Injection timing adjustment_08

Pump speed r/min 900 900 900

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 46.3 45.3 47.3

Remarks
CBS

Injection quantity adjustment

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 19.9 25.9

Difference in delivery mm3/st. 7

Basic *

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

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 250 250 250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure kPa 206 177 235

Pressure kgf/cm2 2.1 1.8 2.4

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 2175 2175 2175

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 2.5 2.3 2.7

Basic *

_02

Pump speed r/min 1050 950 1150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 0.5 0.5 0.5

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 2.5 2.2 2.8

_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 5.7 5.2 6.2

_05

Pump speed r/min 2175 2175 2175

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 9 8.6 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 1.6 1.5 1.7

BCS stroke mm 2.9 2.8 3

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 S1. 2. Apply negative pressure P1 kPa {P2 mmHg} to the actuator and confirm that it moves through its full stroke. (A) Control lever (Idling position)
----------
S1=1+1mm P1=-53.3kPa P2=-400mmHg
----------

Information:

Illustration 8 g01455580
(6) 294-3395 Exhaust Support Assembly
Make four mounting holes for 294-3395 Exhaust Support Assembly (6) in the location (designated with a circle) which is shown in Illustration 8.
Illustration 9 g01456256
(17) 8T-4223 Hard Washers (18) 8T-4244 Nuts (19) 8T-4648 Bolt (20) 8T-4956 Bolt (21) 8T-6868 Bolts
Install exhaust support assembly (6) by using two 8T-6868 Bolts (21), one 8T-4648 Bolt (19), one 8T-4956 Bolt (20), four 8T-4223 Hard Washers (17), and four 8T-4244 Nuts (18). Refer to Illustration 9.
Illustration 10 g01456263
(9) 295-3044 Exhaust Support Groups (Lower half)
Remove the upper clamp from each 295-3044 Exhaust Support Group (9) by removing the two bolts and two hard washers. Keep the four bolts, the four hard washers, and the two upper clamps together. These parts will be reinstalled in Step 15.
Use four 8T-4956 Bolts (20) and four 8T-4223 Hard Washers (17) to install both 295-3044 Exhaust Support Groups (9) to exhaust support assembly (6). Refer to Illustration 10.
Illustration 11 g01456281
(5) 294-3065 Diesel Particulate Filter Group
To facilitate handling, remove the filter units from 294-3065 Diesel Particulate Filter Group (5) by removing the two clamps (including gaskets) closest to the rectangular intake manifold. Place the filter units, clamps, and gaskets aside.Note: Handle the removed filter units with extra care, as the internal structure is subject to damage due to impact, dropping, etc. Do not allow the inside of the filter units to get wet.
Install 294-3065 Diesel Particulate Filter Group (5) by aligning the mounting holes in the intake manifold with the mounting holes in the welded exhaust support assembly (7). Secure the intake manifold to the exhaust support assembly by using two 8T-4956 Bolts (20), two 8T-4223 Hard Washers (17), and two 8T-4244 Nuts (18). Refer to Illustration 11.
Reattach the lower filter unit to the intake manifold by reinstalling the clamp and the gasket that was removed in Step 12. Repeat for the upper filter unit.
Illustration 12 g01456285
Align the mounting holes in the upper half of 295-3044 Exhaust Support Group (9) with the mounting holes in the lower half of the exhaust support group (9). Reinstall the two bolts (9a) and the two hard washers (9b). Repeat for the other exhaust support group (9). Refer to Illustration 12.
Connect the straight end of exhaust tube assembly (8) to the manifold inlet pipe of the Diesel Particulate Filter Group. Use one 190-5341 Clamp (3)