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104741-1422 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411422 8944528372


 

Information injection-pump assembly

ZEXEL 104741-1422 1047411422
ISUZU 8944528372 8944528372
104741-1422 INJECTION-PUMP ASSEMBLY
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Components :

0. INJECTION-PUMP ASSEMBLY 104741-1422
1. _
2. FUEL INJECTION PUMP
3. NUMBER PLATE
4. _
5. CAPSULE
6. ADJUSTING DEVICE
7. NOZZLE AND HOLDER ASSY 105118-4404
8. Nozzle and Holder
9. Open Pre:MPa(Kqf/cm2) 18.1(185)
10. NOZZLE-HOLDER 105048-3220
11. NOZZLE 105017-0550

Include in #2:

104741-1422 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 104741-1422 1047411422
ISUZU 8944528372 8944528372


Zexel num
Bosch num
Firm num
Name
104741-1422 
104741-1425 
 
8944528372  ISUZU
INJECTION-PUMP ASSEMBLY
4JB1CGT *

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   1250 1250 1250
Boost pressure kPa   46.65 45.3 48
Boost pressure mmHg   350 340 360
Average injection quantity mm3/st.   49.4 48.9 49.9
Difference in delivery mm3/st.   4.5
Basic   *
Remarks
CBS  
Injection timing adjustment_02
Pump speed r/min   1250 1250 1250
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   61.3 60.8 61.8
Difference in delivery mm3/st.   3.5
Basic   *
Remarks
Full  
Injection timing 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.   16.6 13.1 20.1
Injection timing adjustment_04
Pump speed r/min   1800 1800 1800
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   58.6 55.1 62.1
Injection timing adjustment_05
Pump speed r/min   1250 1250 1250
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   61.3 60.3 62.3
Remarks
Full  
Injection timing adjustment_06
Pump speed r/min   1250 1250 1250
Boost pressure kPa   46.65 45.3 48
Boost pressure mmHg   350 340 360
Average injection quantity mm3/st.   49.4 48.4 50.4
Remarks
CBS  
Injection timing adjustment_07
Pump speed r/min   900 900 900
Boost pressure kPa   46.65 45.3 48
Boost pressure mmHg   350 340 360
Average injection quantity mm3/st.   49.5 46 53
Injection timing adjustment_08
Pump speed r/min   750 750 750
Boost pressure kPa   24 22.7 25.3
Boost pressure mmHg   180 170 190
Average injection quantity mm3/st.   39.4 35.9 42.9
Injection timing adjustment_09
Pump speed r/min   600 600 600
Boost pressure kPa   13.35 12 14.7
Boost pressure mmHg   100 90 110
Average injection quantity mm3/st.   36 32 40
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.   16.6 13.6 19.6
Difference in delivery mm3/st.   4.5
Basic   *
Injection quantity adjustment_02
Pump speed r/min   2600 2600 2600
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   5
Governor adjustment
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   7 5 9
Difference in delivery mm3/st.   2
Basic   *
Governor adjustment_02
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   7 5 9
Governor 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.   3
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.   80 60 100
Basic   *
Speed control lever angle
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   0 0 0
Remarks
Magnet OFF  
0000000901
Pump speed r/min   1600 1600 1600
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Overflow quantity with S/T OFF cm3/min   561 432 690
Remarks
MEASURE  
Stop lever angle
Pump speed r/min   1600 1600 1600
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Pressure with S/T OFF kPa   490.5 471 510
Pressure with S/T OFF kgf/cm2   5 4.8 5.2
Basic   *
Stop lever angle_02
Pump speed r/min   1600 1600 1600
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Pressure with S/T OFF kPa   490.5 471 510
Pressure with S/T OFF kgf/cm2   5 4.8 5.2
Stop lever angle_03
Pump speed r/min   1800 1800 1800
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Pressure with S/T OFF kPa   539.5 510 569
Pressure with S/T OFF kgf/cm2   5.5 5.2 5.8
0000001101
Pump speed r/min   1600 1600 1600
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Timer stroke with S/T OFF mm   5 4.8 5.2
Basic   *
_02
Pump speed r/min   520 520 520
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Timer stroke with S/T ON mm   0.5 0.5
_03
Pump speed r/min   1600 1600 1600
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Timer stroke with S/T OFF mm   5 4.7 5.3
_04
Pump speed r/min   1800 1800 1800
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Timer stroke with S/T OFF mm   6.2 5.8 6.6
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   0.9 0.8 1
BCS stroke mm   4.8 4.7 4.9
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

Test data 104741-1422
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. Must change from ON to OFF at L1. [Lever angle b (from idle).] (A): microswitch fixing bolt
----------
L=6.0mm L1=5.6~6.4mm a=14deg b=13~15deg
----------
T=2~3N-m(0.2~0.3kgf-m) L=6.0mm

0000001901 V-FICD ADJUSTMENT

Test data 104741-1422
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
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This Special Instruction is intended to provide instructions on installing O-Ring seals on the injector sleeves.Required Parts
Table 1
Required Parts    
Part Number     Part Name     Quantity    
227-1200     Injector Sleeve     6    
310-7255     O-Ring Seal     6    
310-7257     O-Ring Seal     6    Required Tools
Table 2
Required Tools    
Part Number     Part Name     Quantity    
221-9777     Sleeve Installer     1    
4C-5552     Large Bore Brush     1    
4C-9507     Retaining Compound     1    Cleaning the Injector Sleeves and Installing O-Ring Seal
Note: Thoroughly clean the injector sleeves with the 4C-5552 Large Bore Brush .Note: Thoroughly clean the bore in the cylinder head for the injector sleeves with the 4C-5552 Large Bore Brush .Note: Do not apply any lubricant to the O-ring seals.
Illustration 1 g01379557
(1) 310-7255 O-Ring Seal (2) 310-7257 O-Ring Seal (3) 227-1200 Injector Sleeve
Install the upper O-Ring (1) on the injector sleeve (3) .Note: The upper O-Ring is dark blue.
Install the lower O-Ring (2) on the injector sleeve (3) .Note: The lower O-Ring (2) is turquoise.
Position the injector sleeve on the 221-9777 Sleeve Installer .
Apply a thin coat of 4C-9507 Retaining Compound around the outer circumference of area (A). Ensure that the retaining compound does not make contact with the O-Ring seal at any time.
Position the injector sleeve (3) in the cylinder head by using the 221-9777 Sleeve Installer .
Slowly push the injector sleeve into the cylinder head by gently tapping with a hammer.Note: Allow the 4C-9507 Retaining Compound to cure for two hours at 21 °C (70 °F) before filling the engine with coolant. Longer curing time is required for lower temperatures.
Install the unit injectors. Refer to Disassembly and Assembly, "Unit Injector-Install" to install the unit injectors.

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