104741-6780 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047416780 8970134680

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-6780 1047416780

ISUZU 8970134680 8970134680

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Cross reference number

ZEXEL 104741-6780 1047416780

ISUZU 8970134680 8970134680

Zexel num

Bosch num

Firm num

Name

104741-6780
104741-6781

8970134680 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1 * K

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 1000 1000 1000

Average injection quantity mm3/st. 41.7 41.2 42.2

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. 38.3 38.3 38.3

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 34.4 34.4 34.4

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 41.7 40.7 42.7

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. 43.9 40.9 46.9

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 47.5 44 51

Difference in delivery mm3/st. 5.5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 10.6 7.6 13.6

Difference in delivery mm3/st. 4

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. 10.6 7.6 13.6

Difference in delivery mm3/st. 4

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 5.5 3.5 7.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 5.5 3.5 7.5

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. 60 60 100

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 60 100

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 1600 1600 1600

Overflow quantity with S/T ON cm3/min 490 360 620

Overflow quantity with S/T OFF cm3/min 580 450 710

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1600 1600 1600

Pressure with S/T OFF kPa 451 431 490

Pressure with S/T OFF kgf/cm2 4.6 4.4 5

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1600 1600 1600

Pressure with S/T OFF kPa 451 431 490

Pressure with S/T OFF kgf/cm2 4.6 4.4 5

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1600 1600 1600

Timer stroke with S/T OFF mm 2.2 2 2.4

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Timer stroke with S/T ON mm 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1500 1500 1500

Timer stroke with S/T OFF mm 0.5

Oil temperature degC 50 48 52

_04

Pump speed r/min 1600 1600 1600

Timer stroke with S/T OFF mm 2.2 2 2.4

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 1800 1800 1800

Timer stroke with S/T OFF mm 7 6.7 7.4

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 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. 31 26 36

Test data Ex:

0000001801 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Adjust the actuator rod to obtain S1. 2. Apply negative pressure P1 to the actuator and confirm the full stroke.
----------
S1=1+1mm P1=-53.3kPa(-400mmHg)
----------
S1=1+1mm

0000001901 A/T PLATE ADJUSTMENT

A/T plate adjustment Rotate the control lever from the idle position (B) to the full-speed position (C). Adjust the A/T plate (A) so that (A) (C) - (A) (B) = L1, and fix. When fixing, fix the A/T plate within the range L3 from the center of the control lever's wire hole (hole L2). (B) Idle position (C) Full position
----------
L1=32.9+-1mm L2=Dia.8.5mm L3=Dia.9.2mm
----------
L3=Dia.9.2mm L4=169.8mm L5=12.4mm a=18+-4deg

0000002001 POTENTIOMETER ADJUSTMENT

Adjust the potentiometer so that the output voltage is V1 at the idle lever position (applied voltage Vi).
----------
V1=1+-0.03V Vi=10V
----------

Information:

Termination Date
January 31, 1993Problem
The fuel injection pumps used on certain Remanufactured 1160 and 3208 Engines need to be inspected for gummy deposits.
Affected Product
Model & Identification Number
1160 (57V1-34325)
3208 (9WC1-730; 5CD1-5868; 62W1-68596; 93Z1-8374)
Remanufactured Fuel Pump Part Numbers
0R07660R09030R23840R23860R09020R23740R23850R2877 The above list of remanufactured pumps are affected only if they are stamped with a date code of 12/91 (UMDU) or earlier.
Parts Needed
Not Applicable
Action Required
Before installing or delivering any of the affected product, perform the following steps to ensure the internal fuel injection pump components are not stuck due to fuel pump gumming:
1. Remove the top cover of the fuel injection pump and check to ensure that all sleeves and levers are free and there are no gummy deposits on any of these components.2. If inspection performed in Step 1 indicates everything is clean, install top cover and return to parts stock.3. If inspection reveals components have gummy deposits, remove 12 ounces of fuel from the fuel pump housing and replace it with: - Fuel Injector Cleaner or
- Carburetor/Choke Cleaner
4. Allow the components to soak in cleaning solution for 45 minutes, then rotate the engine crankshaft to rotate the fuel injection pump (on pumps only, rotate the fuel pump camshaft). This will ensure the components have the gummy deposits removed. If the engine or fuel pump will be used immediately, install the cover on the fuel injection pump, and install or deliver the engine or pump.5. If the engine or fuel pump will be returned to stock, DO NOT leave the fuel injection pump full of cleaning solution because it may not contain any rust inhibitors. Remove the cleaning solution, fill the fuel injector pump with clean diesel fuel, and install the cover on the pump.Service Claim Allowances
It is a .5-hr. job to inspect the pump. An additional .5-hr. may be claimed if cleaning is required.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.