104741-1381 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411381 8944694150

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-1381 1047411381

ISUZU 8944694150 8944694150

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Cross reference number

ZEXEL 104741-1381 1047411381

ISUZU 8944694150 8944694150

Zexel num

Bosch num

Firm num

Name

104741-1381

8944694150 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. 56 55.5 56.5

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 80 78.7 81.3

Boost pressure mmHg 600 590 610

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. 56 55 57

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1150 1150 1150

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

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 58.7 69.7

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 530 510 550

Pressure with S/T OFF kgf/cm2 5.4 5.2 5.6

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 530 510 550

Pressure with S/T OFF kgf/cm2 5.4 5.2 5.6

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 706 667 745

Pressure with S/T OFF kgf/cm2 7.2 6.8 7.6

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=6.0+-0.2mm

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:

Clean any machining debris that may be on the inside of the flywheel housing.Ensure that the debris guard is clean. A clean guard will ensure that no machining debris falls into the engine when the debris guard is removed.
Remove the debris guard from the inside of the flywheel housing.Install the Pipe Adapters and Sensors
Use 12 5P-2424 Bolts and 118-0275 Washers in order to install wheel (1) onto the cam gear.
Illustration 24 g01323683
(K) Installation guide for the pipe adapters
Illustration 25 g01323672
(1) 284-8910 Wheel
Install the installation guide for the pipe adapters.The installation guide must be installed on the evenly spaced teeth of wheel (1). Refer to Illustration 25.
Illustration 26 g01323669
(2) Fabricated pipe adapters
Install the top and the bottom pipe adapters (2) that were fabricated from the design in Illustration 6.
Use 7M-7456 Bearing Mount Compound to coat the outside of pipe adapter (2) .
Ensure that the adapter is properly aligned with the machined hole.
Illustration 27 g01323703
(L) Bushing driver (2) Pipe adapter
Illustration 28 g01323665
Pipe adapter (2) in contact with installation guide (K)
Use bushing driver (L) to install pipe adapters (2) .Continue installing the pipe adapters until the adapters contact the installation guide. The guide will not wiggle when the adapters are properly installed. Refer to Illustrations 27 and 28.
Remove the installation guide.
Illustration 29 g01324920
Correct alignment of the center pole of the speed sensor (3) Center pole of the speed sensor
Inspect the hole in pipe adapters (2) .The tooth of wheel (1) must be in the center of the hole in the pipe adapter. In order to ensure that the speed sensor will operate correctly, the center of the speed sensor must align with a tooth on wheel (1). Refer to Illustration 29 for an example of the correct alignment.
Illustration 30 g01323661
183-8597 Speed Sensor Gp
Illustration 31 g01323666
Speed sensors (5) Primary speed sensor (6) Secondary speed sensor
Install 3K-0360 O-Ring Seals with primary speed sensor (5) and secondary speed sensor (6) . 183-8597 Speed Sensor Gp Torque ... 37 4 N m (27 3 lb ft) Clearance between tip of sensor and the wheel ... 0.750 mm to 2.000 mm (0.0295 inch to 0.0787 inch)Note: Note the position of extra tooth (7) in relation to primary speed sensor (5) .Note: The 284-8909 Camshaft Gear may need repositioned in order to adjust the position of wheel (1).
Illustration 32 g01323706
Typical example of wheel (1) in standard rotation (7) Extra tooth
Illustration 33 g01323668
Typical example of wheel (1) in reverse rotation
Adjust the 284-8910 Wheel .
Align the first tooth after extra tooth (7) with the center of the primary speed sensor.Refer to Illustration 32.
Torque the bolts to 120 N m (89 lb ft).
Recheck the alignment of the first tooth after extra tooth (7) and the primary speed sensor.
Install the 240-9736 Cylinder Block Cover Gp .
Use 0S-1594 Bolts and 3V-3308 Hard Washers in order to install the two 4B-3140 Covers and the 1W-1960 Gaskets onto the front housing of the engine.
Use 3B-1915 Bolts and 3V-3308 Hard Washers in order to install the 7E-5420 Cover and