104740-1880 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401880 8970255450

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1880 1047401880

ISUZU 8970255450 8970255450

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Cross reference number

ZEXEL 104740-1880 1047401880

ISUZU 8970255450 8970255450

Zexel num

Bosch num

Firm num

Name

104740-1880
104740-1881

8970255450 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 500 500 500

Average injection quantity mm3/st. 49.9 49.9 49.9

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 49.1 48.1 50.1

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2150 2150 2150

Average injection quantity mm3/st. 47.6 47.6 47.6

Oil temperature degC 52 50 54

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 2500 2500 2500

Average injection quantity mm3/st. 15.4 12.4 18.4

Difference in delivery mm3/st. 4.5

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 425 425 425

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 425 425 425

Average injection quantity mm3/st. 10.5 8.5 12.5

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. 55 55 85

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 425 425 425

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 1750 1750 1750

Pressure kPa 588 559 617

Pressure kgf/cm2 6 5.7 6.3

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 600 600 600

Timer stroke mm 0 0 0

Oil temperature degC 50 48 52

_03

Pump speed r/min 1010 1010 1010

Timer stroke mm 0.5 0.5

Oil temperature degC 50 48 52

_04

Pump speed r/min 1250 1250 1250

Timer stroke mm 2 1.6 2.4

Oil temperature degC 50 48 52

_05

Pump speed r/min 1750 1750 1750

Timer stroke mm 4.2 4 4.4

Basic *

Oil temperature degC 50 48 52

_06

Pump speed r/min 2150 2150 2150

Timer stroke mm 5.9 5.4 6.4

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

_02

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 35 34 36

Timer stroke TA mm 3.5 3.1 3.9

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 25 24 26

Timer stroke TA mm 2.6 2 3.2

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. 38 33 43

Test data Ex:

0000001801 A/T PLATE ADJUSTMENT

A/T plate adjustment 1. Turn the control lever from the idle position (B) to the Full speed position (C) 2. Adjust the A/T plate (D) so that (A)(C) - (A)(B) = L3, then fix.
----------
L3=33+-0.5mm
----------
L1=95.5mm L2=109.5mm L3=33+-0.5mm T=3.5~5N-m(0.35~0.5kgf-m)

Information:

White Smoke
Possible Causes/CorrectionsCold Outside Temperatures
When the air outside is cold, the cylinder temperature is cooler. Not all the fuel will burn in the cylinders. The fuel which does not burn comes out the exhaust as white smoke. White smoke is normal in cold temperatures until the engine operates long enough to become warm. There will be less white smoke if No. 1 diesel fuel is used.Long Idle Periods
When an engine runs at idle speed for a long period of time, the cylinders cool and all of the fuel does not burn. Do not idle an engine for a long period of time. Stop an engine when it is not in use. If long idle periods are necessary, use No. 1 diesel fuel.Engine Operating Temperature Too Low
This can cause white smoke on startup. If the smoke is slow to clear from the exhaust, check and make a replacement of the thermostat if needed.Low Quality Fuel
Test the engine using fuec according to recommendations by Caterpillar Inc. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines.Air In Fuel System
With air in the fuel system, the engine will normally be difficult to start, run rough, and release a large amount of white smoke. If the engine will not start, loosen a fuel injection line nut at the through the head adapter and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine still does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the through head adapters until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air cannot be removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leakage at the connections between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. If there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.Fuel Injection Timing Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual.Valve Adjustment Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in) and exhaust valve clearance is 0.76 mm (.030 in).Bad Fuel Nozzle(s)
Bad fuel nozzles will normally cause the engine to "misfire" and run rough, but can cause too much smoke with the engine still running smooth. Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual.Misfiring Cylinder(s)
See Misfiring And Running Rough.Coolant Leakage Into Combustion Chamber
Coolant in the combustion chamber can