104746-1341 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047461341 8971078650

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104746-1341 1047461341

ISUZU 8971078650 8971078650

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Cross reference number

ZEXEL 104746-1341 1047461341

ISUZU 8971078650 8971078650

Zexel num

Bosch num

Firm num

Name

104746-1341
104746-1342

8971078650 ISUZU

INJECTION-PUMP ASSEMBLY
4JG2 * K

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 154805-7320

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. 60.9 60.4 61.4

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. 60 60 60

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60.9 59.9 61.9

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1440 1440 1440

Average injection quantity mm3/st. 58.9 58.9 58.9

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 59.2 59.2 59.2

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 19.6 16.6 22.6

Difference in delivery mm3/st. 5.5

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. 19.6 16.6 22.6

Difference in delivery mm3/st. 5.5

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 13.2 11.2 15.2

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 13.2 11.2 15.2

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. 74 69 79

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 74 69 79

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 400 400 400

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 1000 1000 1000

Overflow quantity cm3/min 680 550 810

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1000 1000 1000

Pressure kPa 422 393 451

Pressure kgf/cm2 4.3 4 4.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Pressure kPa 422 393 451

Pressure kgf/cm2 4.3 4 4.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 520 520 520

Pressure kPa 255 206 304

Pressure kgf/cm2 2.6 2.1 3.1

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1700 1700 1700

Pressure kPa 657 608 706

Pressure kgf/cm2 6.7 6.2 7.2

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1000 1000 1000

Timer stroke mm 2.5 2.3 2.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1700 1700 1700

Timer stroke mm 5.8 5.5 6.1

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 520 520 520

Timer stroke mm 0.5 0.1 1.3

Oil temperature degC 50 48 52

_04

Pump speed r/min 1000 1000 1000

Timer stroke mm 2.5 2.3 2.7

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 1440 1440 1440

Timer stroke mm 3.9 3.6 4.2

Oil temperature degC 50 48 52

_06

Pump speed r/min 1700 1700 1700

Timer stroke mm 5.8 5.4 6.2

Basic *

Oil temperature degC 50 48 52

_07

Pump speed r/min 1950 1950 1950

Timer stroke mm 7.8 7.5 8.2

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 31.8 31.3 32.3

Timer stroke TA mm 2.2 2.2 2.2

Timer stroke variation dT mm 0.3 0.1 0.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 31.8 30.8 32.8

Timer stroke variation dT mm 0.3 -0.1 0.7

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 16.7 15.7 17.7

Timer stroke variation dT mm 1 0.4 1.6

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 0.7 0.6 0.8

Pre-stroke mm 0.1 0.08 0.12

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 31 26 36

Test data Ex:

0000001801 W-CSD ADJUSTMENT

Adjustment of the W-CSD Adjustment of the timer advance angle 1. Determine the timer advance angle using the graph (graph TA). 2. Adjust using screw so that the timer advance angle determined in item (1) is obtained. Then fix using nut (B). X:Temperature t (deg C) Y:Timer stroke TA (mm) (S) Cooling water temperature: increase direction (R) Cooling water temperature (deg C) (T) Timer piston stroke (mm) (C) Standard point N:Pump speed
----------
TA=-0.0345t+2.59
----------
N1=500r/min a=20degC b=-20degC c=1.9+-0.4mm d=3.3+-0.6mm

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Insert a shim L1 between the control lever (A) and the idle adjusting screw (B) and adjust using the FICD adjusting screw (C) so that the actuator moves through its full stroke. Then, fix using nut (D). If adjustment with the FICD adjusting screw (C) is not possible, adjust by moving the actuator stroke with (E) and (F). 2. Apply P1 to the actuator and confirm the full stroke. After release, confirm that the gap between the control lever (A) and the FICD adjusting screw (C) is at least L2. (G) L2 or above at actuator release (H) Actuator stroke L3
----------
L1=0.90+-0.1mm L2=0.5mm L3=5mm P1=-53.3kPa(-400mmHg)
----------
L1=0.9+-0.1mm T1=1.2~1.5N-m(0.12~0.15kgf-m) T2=3.4~4.9N-m(0.35~0.50kgf-m)

0000002001 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

0000002101 POTENTIOMETER ADJUSTMENT

A:Lever position V:Output voltage C:Lever angle Vi:Applied voltage D:Full speed E:Idle
----------

----------
V1=8.2+-0.03V V2=3.94--V V3=10V V4=10V C1=31+-5deg C2=0deg

0000002201 STARTING I/Q ADJUSTMENT

Starting injection quantity adjustment Adjust the adjusting bolt A so that the starting injection quantity adjustment is within the standards. Fix using nut (B). Screw (A) protrusion: L C = stop lever D = no clearance
----------
L=2~7mm
----------
L=2~7mm T=6~9Nm(0.6~0.9kgfm) SW=SW10

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 (15.0990 .0064 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) loose Main 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 7M7456 Bearing Mount) ... 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)