104742-1330 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047421330 8970134571

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104742-1330 1047421330

ISUZU 8970134571 8970134571

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Cross reference number

ZEXEL 104742-1330 1047421330

ISUZU 8970134571 8970134571

Zexel num

Bosch num

Firm num

Name

104742-1330
104742-1331

8970134571 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1 *

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

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. 49.8 49.3 50.3

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 37.5 37.5 37.5

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 39.4 39.4 39.4

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 49.8 48.8 50.8

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 56.4 56.4 56.4

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 59.3 59.3 59.3

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 14.9 11.9 17.9

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. 14.9 11.9 17.9

Difference in delivery mm3/st. 4

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 385 385 385

Average injection quantity mm3/st. 5.9 3.9 7.9

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 385 385 385

Average injection quantity mm3/st. 5.9 3.9 7.9

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 385 385 385

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 900 900 900

Overflow quantity with S/T ON cm3/min 530 400 660

Overflow quantity with S/T OFF cm3/min 530 400 660

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1600 1600 1600

Pressure with S/T OFF kPa 539 510 568

Pressure with S/T OFF kgf/cm2 5.5 5.2 5.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1600 1600 1600

Pressure with S/T OFF kPa 539 510 568

Pressure with S/T OFF kgf/cm2 5.5 5.2 5.8

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1600 1600 1600

Timer stroke with S/T OFF mm 5.5 5.3 5.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 700 700 700

Timer stroke with S/T ON mm 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1400 1400 1400

Timer stroke with S/T OFF mm 1.7 1.3 2.1

Oil temperature degC 50 48 52

_04

Pump speed r/min 1600 1600 1600

Timer stroke with S/T OFF mm 5.5 5.3 5.7

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 1800 1800 1800

Timer stroke with S/T OFF mm 7.4 7.1 7.8

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 4.9 5.1

MS dimension mm 0.8 0.7 0.9

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 MICROSWITCH ADJUSTMENT

Microswitch adjustment (1)Insert a shim thickness t between the control lever and the full stopper screw and fix the control lever. (2)Move the microswitch adjusting plate in the direction of the arrow and fix the plate where the switch turns from ON to OFF. (3)After adjusting the microswitch, the distance between the plate and the roller at idle must not exceed L. (4)The plate must be adjusted to a position where the microswitch turns from ON to OFF. (5)Insert shim at FULL side. A:Idle position B:Plate
----------
t=1.3+-0.3mm L=2.5mm
----------
T=2.0~2.9N-m(0.2~0.3kgf-m) L=2.5--mm t=1.3+-0.3mm

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Adjust to obtain S. 2. Set at L when negative pressure P1 is applied to the actuator. To adjust the stroke adjust the actuator's stroke adjusting screw (C). (A) Control lever (B) Lock nut (Tightening torque T) (C) Stroke adjusting screw
----------
S=1+1mm L=1.6+-0.2mm P1=-53.0kPa(-400mmHg) T=1.2~1.5N-m(0.12~0.15kgf-m)
----------
S=1+1mm L=1.6+-0.2mm T=1.2~1.5N-m(0.12~0.15kgf-m)

Information:

(1) Thickness of spacer plate ... 9.970 0.025 mm (.3925 .0010 in) Thickness of spacer plate gasket ... 0.208 0.025 mm (.0082 .0010 in) For height of liner over top of spacer plate make reference to Cylinder Liner Projection.(2) Camshaft bearing bore (installed) ... 58.80 0.06 mm (2.315 .002 in) Bore in block for camshaft bearings ... 65.100 0.025 mm (2.5630 .0010 in)(3) Bore in block for main bearings (standard size) ... 96.926 0.013 mm (3.8160 .0005 in) Bore in block for main bearings 0.51 mm (.020 in) oversize ... 97.436 0.013 mm (3.8361 .0005 in)(4) Dimension from center of main bearing bore to top of cylinder block (new) ... 383.515 0.165 mm (15.099 .0065 in)(5) Dimension from center of main bearing bore to bottom of cylinder block (new) 153.99 0.10 mm (6.063 .004 in)(6) Torque for bolts holding bearing caps for main bearings: a. Put 2P2506 Thread Lubricant on threads and washer face.b. Tighten all bolts to ... 41 4 N m (30 3 lb ft)c. Put a mark on each bolt and cap.d. Tighten all bolts from mark ... 90 5° Install bearing caps with the part number toward the front of the engine. Be sure that the mark (number) on the bearing cap next to the bolt hole is in agreement with the mark in the cylinder block.(7) Clearance between main bearing cap and cylinder block ... 0.033 mm (.0013 in) tight to ... 0.043 mm (.0017 in) looseMain bearing cap width ... 165.095 0.020 mm (6.4998 .0008 in)Width of cylinder block for main bearing cap ... 165.100 0.018 mm (6.5000 .0007 in) (8) Piston cooling orifice.
There are holes in the bores for the main bearings, between the cylinders for piston cooling orifices. These holes must have orifices (8) installed.
(9) Distance two dowels extend from the surface of the cylinder block ... 19.8 0.5 mm (.78 .02 in)(10) Distance hollow dowel extends from the surface of the cylinder block ... 16.0 0.5 mm (.63 .02 in)(11) Depth to install two dowels below the surface of the cylinder block (apply Loctite #11358) ... 1.0 0.5 mm (.04 .02 in)(12) Distance dowels extend from the front face of the cylinder block ... 22.4 0.5 mm (.88 .02 in)(13) Distance stud extends from the front face of the cylinder block ... 15.7 0.5 mm (.62 .02 in)(14) Distance two dowels extend from the rear face of the cylinder block ... 12.7 0.5 mm (.50 .02 in)