104740-1830 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401830 8970255400

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1830 1047401830

ISUZU 8970255400 8970255400

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Cross reference number

ZEXEL 104740-1830 1047401830

ISUZU 8970255400 8970255400

Zexel num

Bosch num

Firm num

Name

104740-1830
104740-1831

8970255400 ISUZU

INJECTION-PUMP ASSEMBLY
4FG1 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

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. 49.1 48.6 49.6

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 2250 2250 2250

Average injection quantity mm3/st. 32.5 30.9 34.1

Difference in delivery mm3/st. 4

Oil temperature degC 52 50 54

Injection timing adjustment_03

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 33.5 32 35

Difference in delivery mm3/st. 4

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 34 33 35

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 28 26.5 29.5

Difference in delivery mm3/st. 3.5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 15.4 12.4 18.4

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2850 2850 2850

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 15.5 14.5 16.5

Difference in delivery mm3/st. 4.5

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10.5 8.5 12.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 75 73 77

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. 55 55 75

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 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 1750 1750 1750

Pressure kPa 588 568 608

Pressure kgf/cm2 6 5.8 6.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Pressure kPa 471 451 491

Pressure kgf/cm2 4.8 4.6 5

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1750 1750 1750

Timer stroke mm 4.2 4 4.4

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 570 470 670

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 3.9 3.7 4.1

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1800 1800 1800

Timer stroke mm 6.7 6.3 7.1

Oil temperature degC 50 48 52

_05

Pump speed r/min 2250 2250 2250

Timer stroke mm 9 8.7 9.4

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 1750 1750 1750

Average injection quantity mm3/st. 35 34 36

Timer stroke TA mm 3.5 3.3 3.7

Basic *

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

Pre-stroke mm 0.2 0.18 0.22

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. At idle lever position L1, adjust to obtain S. (Apply negative pressure P1 {P2}). 2. Confirm that L in the figure changes to L2 when negative pressure P3 {P4} is applied to the actuator. To adjust the stroke adjust the actuator's stroke adjusting screw (C) (Tightening torque T). (A) Control lever (B): lock nut (C): stroke adjusting screw (D): Actuator (E): actuator shaft
----------
S=1+1(mm) L1=0(mm) L2=0.56+-0.2(mm) P1=0(kPa) P2=0(mmHg) P3=-53.3(kPa) P4=-400(mmHg) T=1.2~1.5(N-m)(0.12~0.15(kgf-m))
----------
S=1+1(mm)

Information:

Make reference to Guideline For Reusable Parts; Pistons, Form No. SEBF8049; Cylinder Liners, Form No. SEBF8068; and Piston Pins And Retaining Rings, Form No. SEBF8051. For installation, number on tab groove side of connecting rod is to be positioned toward opposite side of engine from camshaft.Top And Intermediate Ring
The 8T3150 Keystone Piston Ring Groove Gauge is necessary for measuring ring grooves in keystone style pistons. For correct use of the gauge group, see the instruction card that is with the gauge group.Install piston rings with "UP" side toward top of piston.(1) Top Ring has the mark "UP-1."(2) Intermediate ring has the mark "UP-2".Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 137.16 mm (5.400 in):Top ring ... 0.724 0.190 mm (.0285 .0075 in)Intermediate ring ... 1.080 0.190 mm (.0425 .0075 in)Increase in clearance between ends of piston rings for each 0.03 mm (.001 in) increase in cylinder liner bore size ... 0.08 mm (.003 in)Oil Control Ring
(3) Install oil control ring with the gap in the spring 180° away from the gap in the ring. White portion of spring must be visible at the ring end gap.Width of groove in piston for piston ring (new) ... 3.210 0.013 mm (.1255 .0005 in)Thickness of piston ring (new) ... 3.137 0.013 mm (.1235 .0005 in)Clearance between groove and piston ring (new) ... 0.051 0.025 mm (.0020 .0010 in)Maximum permissible clearance (worn) ... 0.15 mm (.006 in)Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 137.16 mm (5.400 in) ... 0.572 0.190 mm (.0225 .0075 in)Increase in clearance between ends of piston ring for each 0.03 mm (.001 in) increase in cylinder liner bore size ... 0.08 mm (.0003 in)Piston Pin Bore
(4) Bore in piston for pin. 1991 Model with elliptical pin bore (310 - 425 hp) Vertical ... 50.814 0.004 mm (2.0005 .0001 in)Horizontal ... actual vertical diameter plus0.032 to .048 mm (.0012 to .0019 in)Clearance between pin and bore in piston ... 0.010 to 0.028 mm (.0004 to .0011 in)Permissible clearance (worn) ... 0.05 mm (.002 in)Pin diameter ... 50.795 0.005 mm (1.9998 .0002 in) Low Crevice Volume and Gallery Pistons Bore in piston for pin ... 50.814 0.004 mm (2.0005 .0001 in)Clearance between pin and bore in piston ... 0.010 to 0.028 mm (.0004 to .0011 in)Permissible clearance (worn) ... 0.05 mm (.002 in)Pin diameter ... 50.795 0.005 mm (1.9998 .0002 in)All Other Pistons Bore in piston for pin ... 50.815 0.008 mm (2.0006 .0003 in)Clearance between pin and bore in piston ... 0.007 to 0.032 mm (.0003 to .0013 in)Permissible clearance (worn) ... 0.05 mm (.002 in)Pin diameter ... 50.795 0.005 mm (1.9998 .0002 in)