104740-1590 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401590 8944696820

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1590 1047401590

ISUZU 8944696820 8944696820

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Cross reference number

ZEXEL 104740-1590 1047401590

ISUZU 8944696820 8944696820

Zexel num

Bosch num

Firm num

Name

104740-1590
104740-1592

8944696820 ISUZU

INJECTION-PUMP ASSEMBLY
4FG1 *

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

Average injection quantity mm3/st. 50.9 50.4 51.4

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 49.5 48 51

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 50.9 49.9 51.9

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2200 2200 2200

Average injection quantity mm3/st. 42.7 41.1 44.3

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 24.9 21.9 27.9

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 24.9 21.9 27.9

Difference in delivery mm3/st. 4.5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2850 2850 2850

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10.3 8.3 12.3

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10.3 8.3 12.3

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50 50 70

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50 50 70

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 350 350 350

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

Overflow quantity cm3/min 420 290 550

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Pressure kPa 451 431 471

Pressure kgf/cm2 4.6 4.4 4.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Pressure kPa 451 431 471

Pressure kgf/cm2 4.6 4.4 4.8

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke mm 1.7 1.5 1.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 930 830 1030

Timer stroke mm 0.5 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Timer stroke mm 1.7 1.5 1.9

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 2000 2000 2000

Timer stroke mm 4.6 4.2 5

Oil temperature degC 50 48 52

_05

Pump speed r/min 2300 2300 2300

Timer stroke mm 5.7 5.4 6.1

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 28.9 28.4 29.4

Timer stroke TA mm 1.3 1.3 1.3

Timer stroke variation dT mm 0.4 0.2 0.6

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 28.9 27.9 29.9

Timer stroke variation dT mm 0.4 0.1 0.7

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 18 17 19

Timer stroke variation dT mm 0.8 0.3 1.3

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 0.9 0.8 1

Control lever angle alpha deg. -2 -6 2

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

Information:

Recommended Procedure
A. Outside Leaks1. Leaks in Hoses or Connections ... Check all hoses and connections for visual signs of leakage. If no leaks are seen, look for damage to hoses or loose clamps.2. Leaks in the Radiator and/or Expansion Tank ... Put pressure to the radiator and/or expansion tank with the 9S8140 Cooling System Pressurizing Pump Group and check for leaks.3. Leaks in the Heater ... Put pressure to the cooling system with the 9S8140 Cooling System pressurizing Pump Group and check the heater for leaks.4. Leaks in the Water Pump ... Check the water pump for leaks before starting the engine, then start the engine and look for leaks. If there are leaks at the water pump, repair or install a new water pump.5. Cylinder Head Gasket Leakage ... Look for leaks along the surface of the cylinder head gasket. If you see leaks, install a new head gasket.B. Coolant Leaks at the Overflow Tube6. Bad Pressure Cap or Relief Valve ... Check the sealing surfaces of the pressure cap and the radiator to be sure the cap is sealing correctly. Check the opening pressure and sealing ability of the pressure cap or relief valve with the 9S8140 Cooling System Pressurizing Pump Group.7. Engine Runs Too Hot ... If coolant temperature is too high, pressure will be high enough to move the cap off of the sealing surface in the radiator and cause coolant loss through the overflow tube. See "Above Normal Heating" in COOLING SYSTEM Chart.8. Expansion Tank Too Small or Installed Wrong ... The expansion tank can be either a part of the radiator or it can be installed separately from the radiator. The expansion tank must be large enough to hold the expansion of the coolant as it gets warm or has sudden changes in pressure. Make sure the expansion tank is installed correctly, and the size is according to the recommendations of the Truck Manufacturer.9. Cylinder Head Gasket Leakage, or Crack(s) in Cylinder Head or Cylinder Block ... Remove the radiator cap and with the engine running look for air bubbles in the coolant. Bubbles in the coolant are a sign of probable leakage at the head gasket. With the engine not running, check each cylinder with the cylinder leakage tester. Special Instruction, Form No. GMG00694 gives the test procedure. If you see air bubbles in the coolant during this test, there is a leak of combustion gas into the cooling system. Remove the cylinder heads from the engine. Check cylinder heads, cylinder walls and head gasket surface of the cylinder block for cracks. When installing heads, use new head gasket.C. Inside Leakage10. Cylinder Head Gasket Leakage ... If the cylinder head gasket leaks between a water passage and an opening into the crankcase, coolant will get into the crankcase.11. Crack(s) in Cylinder Head ... Crack(s) in the upper surface of the cylinder head, or an area between a water passage and an opening into the crankcase, can allow