Information injection-pump assembly
ZEXEL
104742-1032
1047421032
ISUZU
8944046182
8944046182
Rating:
Cross reference number
ZEXEL
104742-1032
1047421032
ISUZU
8944046182
8944046182
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
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
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
Right R
(Solenoid timer adjustment condition)
OFF
Injection timing adjustment
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
65.8
65.3
66.3
Difference in delivery
mm3/st.
4
Basic
*
Injection timing adjustment_02
Pump speed
r/min
1900
1900
1900
Average injection quantity
mm3/st.
16.7
13.2
20.2
Injection timing adjustment_03
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
66.4
60.9
71.9
Injection timing adjustment_04
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
65.9
61.9
69.9
Injection timing adjustment_05
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
65.8
64.8
66.8
Injection timing adjustment_06
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
57.1
53.6
60.6
Injection timing adjustment_07
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
65.8
61.3
70.3
Injection quantity adjustment
Pump speed
r/min
1900
1900
1900
Average injection quantity
mm3/st.
16.7
13.7
19.7
Difference in delivery
mm3/st.
7
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
2000
2000
2000
Average injection quantity
mm3/st.
8
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8.5
6.5
10.5
Difference in delivery
mm3/st.
2
Basic
*
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8.5
6.5
10.5
Governor adjustment_03
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
3
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
100
80
120
Basic
*
Speed control lever angle
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF
Magnet OFF
0000000901
Pump speed
r/min
1600
1600
1600
Overflow quantity
cm3/min
621
492
750
Stop lever angle
Pump speed
r/min
1600
1600
1600
Pressure
kPa
588.5
569
608
Pressure
kgf/cm2
6
5.8
6.2
Basic
*
Stop lever angle_02
Pump speed
r/min
1000
1000
1000
Pressure with S/T OFF
kPa
343.5
314
373
Pressure with S/T OFF
kgf/cm2
3.5
3.2
3.8
Stop lever angle_03
Pump speed
r/min
1600
1600
1600
Pressure with S/T OFF
kPa
588.5
569
608
Pressure with S/T OFF
kgf/cm2
6
5.8
6.2
Stop lever angle_04
Pump speed
r/min
1750
1750
1750
Pressure with S/T OFF
kPa
637.5
608
667
Pressure with S/T OFF
kgf/cm2
6.5
6.2
6.8
0000001101
Pump speed
r/min
1600
1600
1600
Timer stroke
mm
3
2.8
3.2
Basic
*
_02
Pump speed
r/min
750
650
850
Timer stroke with S/T ON
mm
0.5
0.5
0.5
_03
Pump speed
r/min
1450
1450
1450
Timer stroke with S/T OFF
mm
0.5
_04
Pump speed
r/min
1500
1500
1500
Timer stroke with S/T OFF
mm
0.9
0.3
1.5
_05
Pump speed
r/min
1600
1600
1600
Timer stroke with S/T OFF
mm
3
2.7
3.3
_06
Pump speed
r/min
1750
1750
1750
Timer stroke with S/T OFF
mm
5.7
5.3
6.1
0000001201
Max. applied voltage
V
16
16
16
Test voltage
V
25
24
26
Timing setting
K dimension
mm
3.1
3
3.2
KF dimension
mm
5.5
5.4
5.6
MS dimension
mm
0.9
0.8
1
Pre-stroke
mm
0.45
0.43
0.47
Control lever angle alpha
deg.
50
46
54
Control lever angle beta
deg.
37
32
42
Test data Ex:
0000001801 TEMP. ADJUST FULL-LOAD SCREW
Temporary full load screw adjustment
Set the full load screw protrusion at L mm at assembly.
----------
L=14.0+-0.5mm
----------
L=14.0+-0.5mm
----------
L=14.0+-0.5mm
----------
L=14.0+-0.5mm
Information:
3.1 Service Standards Table
3.2 Tightening torque table
4. Special Tool
5. Service Procedures
5.1 Removal and Installation
(1) Removal (a) When removing the pressure plate and lever assembly, fix the pressure plate using the special tools, Stopper Bolt and Washer. (C4 and C8 only) (b) Install the special tool, Clutch Alignment Arbor to prevent drop of the clutch disc and then remove the pressure plate and lever assembly.(2) Installation (a) Install the clutch disc using the special tool, Clutch Alignment Arbor. When installing the clutch disc, use care not to confuse the front and reverse sides. Install with the side bearing the part No. facing outside. (b) Install the pressure plate and lever assembly, aligning with the knock pins of the fly wheel. In the case of C4 and C8, install after fixing the pressure plate using special tools, Stopper Bolt and Washer. 1. Before installing the clutch, check and clean the flywheel. If faulty, correct or replace.2. When tightening the bolts, do so in diagonal order and uniformly.3. After installation, be sure to remove the Stopper Bolt and Washer. (C4 and C8 only)(c) Inspection of release lever plate height (at clutch disc replacement only) Using special tool, Clutch Release Lever Aligner, check the height of the clutch cover and release lever plate.If adjustment is necessary, adjust referring to 5.2.2 (3).(d) Adjustment after installation of bearing case. After installation, adjust the free travel (clearance between the release bearing and release lever). 1) Move the lever in the direction to engage the clutch. At a position where a click is heard in the clutch, turn the adjusting bolt A until it is blocked by the stopper, and lock it by turning down the bolt another two or three threads.2) From the position where the release bearing has touched the release lever, turn the adjusting screw B in the direction to disengage the clutch and check to see that the clutch is in disengaged position. Then lock the bolt. When making adjustment, lock in position the ratchet of the lever of the opposite side. 1) Loosen the control ling lock nut and from the position where the release bearing is in contact with the release lever, move back by B1 mm and lock in position (clutch lever setting position when clutch is engaged).2) In the direction to disengage the clutch, lock the air cylinder adjusting bolt at a position B2 mm from the position where the release bearing is in contact with the release lever.5.2 Clutch Proper
Disassembly and inspection
Disassembly and Inspection(1) Removal of clutch cover (a) Matchmark the clutch cover and pressure plate and using special tool, Clutch Installer, compress the pressure spring and remove support lever nut, strap bolt, etc.(b) Slowly loosen the handle of the Clutch Installer to remove the clutch cover.(2) Wear of facing Measure the depth from facing surface to rivet head. If the depth is smaller than the limit, replace the clutch disc assembly.(3) Runout of clutch disc Using a runout tester, measure the runout of the clutch
3.2 Tightening torque table
4. Special Tool
5. Service Procedures
5.1 Removal and Installation
(1) Removal (a) When removing the pressure plate and lever assembly, fix the pressure plate using the special tools, Stopper Bolt and Washer. (C4 and C8 only) (b) Install the special tool, Clutch Alignment Arbor to prevent drop of the clutch disc and then remove the pressure plate and lever assembly.(2) Installation (a) Install the clutch disc using the special tool, Clutch Alignment Arbor. When installing the clutch disc, use care not to confuse the front and reverse sides. Install with the side bearing the part No. facing outside. (b) Install the pressure plate and lever assembly, aligning with the knock pins of the fly wheel. In the case of C4 and C8, install after fixing the pressure plate using special tools, Stopper Bolt and Washer. 1. Before installing the clutch, check and clean the flywheel. If faulty, correct or replace.2. When tightening the bolts, do so in diagonal order and uniformly.3. After installation, be sure to remove the Stopper Bolt and Washer. (C4 and C8 only)(c) Inspection of release lever plate height (at clutch disc replacement only) Using special tool, Clutch Release Lever Aligner, check the height of the clutch cover and release lever plate.If adjustment is necessary, adjust referring to 5.2.2 (3).(d) Adjustment after installation of bearing case. After installation, adjust the free travel (clearance between the release bearing and release lever). 1) Move the lever in the direction to engage the clutch. At a position where a click is heard in the clutch, turn the adjusting bolt A until it is blocked by the stopper, and lock it by turning down the bolt another two or three threads.2) From the position where the release bearing has touched the release lever, turn the adjusting screw B in the direction to disengage the clutch and check to see that the clutch is in disengaged position. Then lock the bolt. When making adjustment, lock in position the ratchet of the lever of the opposite side. 1) Loosen the control ling lock nut and from the position where the release bearing is in contact with the release lever, move back by B1 mm and lock in position (clutch lever setting position when clutch is engaged).2) In the direction to disengage the clutch, lock the air cylinder adjusting bolt at a position B2 mm from the position where the release bearing is in contact with the release lever.5.2 Clutch Proper
Disassembly and inspection
Disassembly and Inspection(1) Removal of clutch cover (a) Matchmark the clutch cover and pressure plate and using special tool, Clutch Installer, compress the pressure spring and remove support lever nut, strap bolt, etc.(b) Slowly loosen the handle of the Clutch Installer to remove the clutch cover.(2) Wear of facing Measure the depth from facing surface to rivet head. If the depth is smaller than the limit, replace the clutch disc assembly.(3) Runout of clutch disc Using a runout tester, measure the runout of the clutch