104741-1380 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411380 8944528170

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-1380 1047411380

ISUZU 8944528170 8944528170

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Cross reference number

ZEXEL 104741-1380 1047411380

ISUZU 8944528170 8944528170

Zexel num

Bosch num

Firm num

Name

104741-1380
104741-1381

8944528170 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1CDT *

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 45.3 44 46.6

Boost pressure mmHg 340 330 350

Average injection quantity mm3/st. 55 54.5 55.5

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1150 1150 1150

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 66.1 65.6 66.6

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 39.9 36.4 43.4

Oil temperature degC 48 46 50

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 27.3 26 28.6

Boost pressure mmHg 205 195 215

Average injection quantity mm3/st. 46.4 46.4 46.4

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 900 900 900

Boost pressure kPa 45.3 44 46.6

Boost pressure mmHg 340 330 350

Average injection quantity mm3/st. 55 54 56

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1150 1150 1150

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 66.1 65.1 67.1

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1900 1900 1900

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 64.2 60.2 68.2

Difference in delivery mm3/st. 5.5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 17.9 14.9 20.9

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2400 2400 2400

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 8

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2300 2300 2300

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 17.9 14.9 20.9

Difference in delivery mm3/st. 4.5

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 6 4 8

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 6 4 8

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

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. 75 75 115

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 92.5 70 115

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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 1700 1700 1700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Oil temperature degC 50 48 52

Remarks
MEASURE

Stop lever angle

Pump speed r/min 1700 1700 1700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure with S/T OFF kPa 441 421 461

Pressure with S/T OFF kgf/cm2 4.5 4.3 4.7

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1700 1700 1700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure with S/T OFF kPa 441 421 461

Pressure with S/T OFF kgf/cm2 4.5 4.3 4.7

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 2000 2000 2000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Pressure with S/T OFF kPa 569 530 608

Pressure with S/T OFF kgf/cm2 5.8 5.4 6.2

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1700 1700 1700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke with S/T OFF mm 4.3 4.1 4.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 820 820 820

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke with S/T ON mm 0.5 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1470 1470 1470

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke with S/T OFF mm 0.5 0.5 0.5

Oil temperature degC 50 48 52

_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke with S/T OFF mm 4.3 4.1 4.5

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke with S/T OFF mm 9.4 9.1 9.8

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 2.8 2.7 2.9

KF dimension mm 5.5 5.4 5.6

MS dimension mm 1 0.9 1.1

BCS stroke mm 4.2 4 4.4

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 37 32 42

Test data Ex:

0000001801 MICROSWITCH ADJUSTMENT

Microswitch adjustment 1.Fix the control lever so that the distance between the control lever and the idling stopper bolt is L (control lever position: a). 2. In the above condition, adjust the installation position of the microswitch so that so that it turns OFF. (A) = microswitch fixing bolt
----------
L=6.0mm a=14deg
----------
T=2~3N-m(0.2~0.3kgf-m) L=6.0mm

0000001901 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
----------
S1=1+1mm

Information:

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Some of the 3408E engines and 3412E engines in the above listed machines may experience hard starting or low power due to oil that is leaking past the poppet valve in the injector. The oil leakage is caused by the operating conditions at either low idle or high idle. Excessive oil leakage can reduce actuation pressure to the fuel injector. This may prevent fuel injection.Solution
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Follow the proper troubleshooting procedure for the correct engine. If the problem is not located and the symptoms that are listed above continue, remove the engine valve covers. Electrically disable the injectors. Crank the engine. Watch the spill ports of the injector for oil leakage. A small amount of oil leakage is acceptable. A continuous stream of oil may mean leakage from the poppet valve. Excessive leakage from the poppet valve may prevent fuel injection.Note: Normal oil pressure during cranking should be 5 MPa (725 psi). Oil pressure below 5 MPa (725 psi) may indicate excessive oil leakage in injectors. Do not replace the oil pump. Service personnel should replace the injectors that have a continuous flow of oil from the oil ports. Injectors that have a continuous flow of oil and injectors that are within the guidelines of warranty can be returned. Injectors that do not have a continuous flow of oil should not be replaced. Injectors that do not have a continuous flow of oil should not be returned.Note: For additional information on the operation of Hydraulic Electronic Unit Injectors HEUI, refer to CD, RENR1390.
Illustration 1 g01308874
(1) Oil drain portThe oil drain ports are located underneath the solenoid. This will direct the oil flow downward. Some oil may also leak from the rectangular slots at the side of the solenoid. Excess oil leakage will still be visible on the cylinder head.