104741-1101 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411101 8941403872

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-1101 1047411101

ISUZU 8941403872 8941403872

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Cross reference number

ZEXEL 104741-1101 1047411101

ISUZU 8941403872 8941403872

Zexel num

Bosch num

Firm num

Name

104741-1101
104741-1102

8941403872 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1BG * 11CJ VE4 VE

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)
Left L

Injection timing adjustment

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.3 43.8 44.8

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. 44.9 41.4 48.4

Difference in delivery mm3/st. 5

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 40.4 38.4 42.4

Difference in delivery mm3/st. 4.5

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.3 43.3 45.3

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 46.9 44.9 48.9

Difference in delivery mm3/st. 5.5

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 45 42.5 47.5

Difference in delivery mm3/st. 5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 20.1 17.1 23.1

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 5

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 20.1 17.1 23.1

Difference in delivery mm3/st. 6

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 8 6 10

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 8 6 10

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. 75 75 115

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 75 115

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 390 390 390

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 1450 1450 1450

Overflow quantity cm3/min 510 380 640

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle

Pump speed r/min 1450 1450 1450

Pressure with S/T OFF kPa 510 490 530

Pressure with S/T OFF kgf/cm2 5.2 5 5.4

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_02

Pump speed r/min 1450 1450 1450

Pressure with S/T OFF kPa 510 490 530

Pressure with S/T OFF kgf/cm2 5.2 5 5.4

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1950 1950 1950

Pressure with S/T OFF kPa 657 628 686

Pressure with S/T OFF kgf/cm2 6.7 6.4 7

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1450 1450 1450

Timer stroke with S/T OFF mm 1.9 1.7 2.1

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 560 560 560

Timer stroke with S/T ON mm 0.5 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1270 1270 1270

Timer stroke with S/T OFF mm 0.5 0.5 0.5

Oil temperature degC 50 48 52

_04

Pump speed r/min 1450 1450 1450

Timer stroke with S/T OFF mm 1.9 1.7 2.1

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 1950 1950 1950

Timer stroke with S/T OFF mm 5.7 5.4 6.1

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001501

Pump speed r/min 1000 1000 1000

Height m 2000 2000 2000

Atmospheric pressure difference kPa -21.9 -21.9 -21.9

Atmospheric pressure difference mmHg -164 -164 -164

Average injection quantity mm3/st. 39.5 39.5 39.5

Decrease qty mm3/st. 4.7 3.7 5.7

Decrease rate % 11 8 14

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 1000 1000

Height m 0 0 0

Atmospheric pressure difference kPa 0 0 0

Atmospheric pressure difference mmHg 0 0 0

Decrease qty mm3/st. 0 0 0

Decrease rate % 0 0 0

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Height m 500 500 500

Atmospheric pressure difference kPa -5.9 -9.2 -2.6

Atmospheric pressure difference mmHg -44 -46.5 -41.5

Oil temperature degC 50 48 52

Remarks
Point of inflection

_04

Pump speed r/min 1000 1000 1000

Height m 2000 2000 2000

Atmospheric pressure difference kPa -21.9 -21.9 -21.9

Atmospheric pressure difference mmHg -164 -164 -164

Decrease qty mm3/st. -4.7 -5.7 -3.7

Decrease rate % -11 -14 -8

Oil temperature degC 50 48 52

Timing setting

K dimension mm 2.8 2.7 2.9

KF dimension mm 5 4.9 5.1

MS dimension mm 1 0.9 1.1

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 35 30 40

Test data Ex:

0000001501 ANEROID COMPENSATOR

ACS adjustment Full load injection quantity at high altitudes and ACS adjusting method 1. Full load injection quantity adjustment (1)Remove the ACS cover and remove the bellows and adjusting shim. (2)Perform all adjustments as per the adjustment standard except for ACS adjustment. 2. ACS adjustment (1)Assemble the ACS cover, bellows and adjusting shim. (2)At pump speed N1, adjust using a shim to obtain the decrease for the altitude shown in the table. X1 = atmospheric pressure X2 = altitude Y = decrease quantity (A) = adjustment value (B) = test value
----------
N1=1000r/min
----------

Information:

Table 1
Sales Model Adaptable to Machines Effective in Production with Machines
D3K 2 S/N:JPJ1-199 S/N:JPJ200-UP
S/N:KL21-208 S/N:KL2209-UP
S/N:LT31-113 S/N:LT3114-UP
S/N:FT31-102 S/N:FT3103-UP
S/N:KF21-174 S/N:KF2175-UP
D4K 2 S/N:KR21-203 S/N:KR2204-UP
S/N:RT31-130 S/N:RT3131-UP
S/N:KM21-196 S/N:KM2197-UP
S/N:MT31-119 S/N:MT3120-UP
D5K 2 S/N:KY21-357 S/N:KY2358-UP
S/N:RRE1-232 S/N:RRE233-UP
S/N:YT31-153 S/N:YT3154-UP
S/N:KW21-308 S/N:KW2309-UP
S/N:WT31-145 S/N:WT3146-UP In the event, the original bolt should come loose or is lost, use one of the following procedures and parts list for reworking the latch assembly.Rework Procedure
Table 2
New Parts List
Item Quantity Part Number Description
1 1 275-0571 Latch Cam
2 1 7X-2619 Bolt
3 1 9X-8256 Washer
4 1 275-0572 Latch As
Illustration 1 g06026857Procedure if the original cam latch retaining bolt is loose
Illustration 2 g06025999
Remove bolt (2), keeping cam latch (1) in position.
Apply Loctite 243 to the threads of bolt (2). Torque the bolt to 6 1 N m (53 9 lb in) using a torque wrench.Procedure if only the original cam latch bolt and cam latch are missing
Illustration 3 g06026021
Install new cam latch (1) to the latch body.
Replace missing retaining bolt with a 7X-2619 Bolt (2) and 9X-8256 Washer (3). This washer is required as the new bolt is too long and will bottom out in the latch body before tightening. Install using Loctite 243. Torque the bolt to 6 1 N m (53 9 lb in) using a torque wrench.Procedure if the original cam latch retaining bolt, cam latch and latch assembly are missing
Illustration 4 g06026825
Illustration 5 g06026826
Illustration 6 g06026831
(E) Side 1 of Retaining Nut
(F) Side 2 of Retaining Nut
Install new latch housing (A), with non-metallic washer (on outside of door) and Latch body/ handle (4) in door.Note: Orient two surfaces (C)and handle as shown in Illustration 5. Lock indicator on outside of handle is at the top.
Secure housing with retaining nut (B) and torque to 15 3 N m (11 2 lb ft), using a torque wrench.Note: During assembly, use four nubs (D) on Side (E) of nut against door.
Remove original bolt (C).
Install latch cam (1).
Apply Loctite 243 to the threads on the original bolt (C). Torque the bolt to 6 1 N m (53 9 lb in).Note: Use torque wrench for tightening.