104741-1741 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411741 8944751612

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-1741 1047411741

ISUZU 8944751612 8944751612

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Cross reference number

ZEXEL 104741-1741 1047411741

ISUZU 8944751612 8944751612

Zexel num

Bosch num

Firm num

Name

104741-1741
104741-1744

8944751612 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

(Solenoid timer adjustment condition) OFF

Injection timing adjustment

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. 51.4 50.9 51.9

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. 63.7 63.2 64.2

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. 22.3 18.8 25.8

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. 58.1 54.6 61.6

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. 63.7 62.7 64.7

Remarks
Full

Injection timing adjustment_06

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. 51.4 50.4 52.4

Remarks
CBS

Injection timing adjustment_07

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. 40.7 38.7 42.7

Injection timing adjustment_08

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. 37.1 33.1 41.1

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. 22.35 19.3 25.4

Difference in delivery mm3/st. 4.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2500 2500 2500

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 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5.1 3.1 7.1

Difference in delivery mm3/st. 2

Basic *

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. 5.1 3.1 7.1

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 385 385 385

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 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Overflow quantity with S/T OFF cm3/min 669 438 900

Stop lever angle

Pump speed r/min 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure kPa 529.5 510 549

Pressure kgf/cm2 5.4 5.2 5.6

Basic *

Stop lever angle_02

Pump speed r/min 500 500 500

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure with S/T ON kPa 490 392 588

Pressure with S/T ON kgf/cm2 5 4 6

Pressure with S/T OFF kPa 78 78

Pressure with S/T OFF kgf/cm2 0.8 0.8

Stop lever angle_03

Pump speed r/min 1450 1450 1450

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 451.5 422 481

Pressure with S/T OFF kgf/cm2 4.6 4.3 4.9

Stop lever angle_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 529.5 510 549

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

Stop lever angle_05

Pump speed r/min 1850 1850 1850

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 578.5 549 608

Pressure with S/T OFF kgf/cm2 5.9 5.6 6.2

0000001101

Pump speed r/min 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke mm 5.2 5 5.4

Basic *

_02

Pump speed r/min 550 550 550

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 1450 1450 1450

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke with S/T OFF mm 2.5 2.1 2.9

_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke with S/T OFF mm 5.2 4.9 5.5

_05

Pump speed r/min 1850 1850 1850

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke with S/T OFF mm 6.15 5.8 6.5

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 4.5 4.4 4.6

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. Insert a shim L mm (control lever position: a) between the control lever and the idling stopper bolt. 2. Move the microswitch in the direction of the arrow so that it turns ON. 3. Move the microswitch again in the direction of the arrow and tighten the microswitch fixing bolt where it turns OFF. Must change from ON to OFF at L1. [Lever angle b (from idle).] (A): microswitch fixing bolt
----------
L=6.0+-0.2mm a=14deg L1=5.6~6.4mm b=13~15deg
----------
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:

Illustration 6 g06613192
Gray locking wedge removed from ECM connector
Remove gray locking wedge from 86-pin connector to provide access to release the DT Pins.Note: Circuit U937 to be removed from pin location number 24 and transferred to pin location 73.Note: Cloth tape will need to be removed to the split in the harness main bundle.Note: The U937 wire can then be routed into the opposite branch to gain enough free length to make the connection.Note: The U939 wire removed from pin location 73 has adequate length to be loaded into location 16.
Transfer and relocate the wires as detailed in Table 2.
Reinstall the locking wedge (B) when all wires have been transferred and relocated.
Illustration 7 g06613197
View of back of ECM connector with connector cover (D) removed
Apply cloth tape to both wire branches from the main bundle of wires up the branches to the harness strain relief strap location.
Illustration 8 g06613199
Connector cover (D) reinstalled with harness secured
(1) 3S-2093 Cable Strap
(D) Connector cover
Reinstall connector cover (D) and secure the harness branches using two cable straps (1).
Use caution when re-engaging the connector with the ECM.
Tighten allen head screw (A).Note: In certain cases, U937 may require lengthening to provide adequate strain relief when relocated in pin 73.Note: Refer to "Soldered Splice","Deutsch connector", or "Sealed Mechanical Splice" for the proper way to extend circuit U937.Soldered Splice
A soldered spliced can be made to extend the wire. Soldered connection will need to be insulated using an appropriately sized adhesive head shrink sleeve.
Illustration 9 g06613210
U937 removed
Remove U937 from ECM connector.
Cut pin off end of wire.
Strip wire 7.5 mm (0.30 inch).
Illustration 10 g06613213
Additional wire soldered to circuit U937
Solder to additional wire to extend U937 and install appropriate sized adhesive head shrink sleeve.
Install pin on end of U937.
Insert U937 into pin 73.
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connector.Deutsch connector
Table 3
Required Parts
Qty Part Number Part Name
1 115-8109 Wire Splice Note: The deutsch connector is a field serviceable alternative to permanent splices. It is made from the same high-quality silicone elastomer as used for the Deutsch connector seals and grommets. The splice body houses a contact retention system that secures a mated pair of contacts in a compact environmentally sealed unit. This splice can also be serviced with standard deutsch connector tools.
Illustration 11 g06613218
Deutsch connector section view
Illustration 12 g06613221
Deutsch connector splice installed
Illustration 13 g06613224
Sufficient strain relief for deutsch connector
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connectorSealed Mechanical Splice
Table 4
Required Parts
Qty Part Number Part Name
1 136-4877 Wire Splice Note: Sealed mechanical splices have head-shrinkable, environmentally sealed sleeves.
Illustration 14 g06613205
Sealed mechanical splice
Select appropriate splice size.
Strip wire 7.5 mm (0.3 inch).
Insert stripped wire into sealed mechanical splice.
Crimp sealed mechanical splice.
Apply heat to the crimped splice until tubing re-covers and adhesive flows.
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connector