104748-1651 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047481651 8944134491


 

Information injection-pump assembly

ZEXEL 104748-1651 1047481651
ISUZU 8944134491 8944134491
104748-1651 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 104748-1651 1047481651
ISUZU 8944134491 8944134491


Zexel num
Bosch num
Firm num
Name
104748-1651 
104748-1653 
 
8944134491  ISUZU
INJECTION-PUMP ASSEMBLY
4EC1 *

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   1250 1250 1250
Average injection quantity mm3/st.   30.2 29.7 30.7
Difference in delivery mm3/st.   2.5
Basic   *
Injection timing adjustment_02
Pump speed r/min   2965 2965 2965
Average injection quantity mm3/st.   11.1 9.6 12.6
Injection timing adjustment_03
Pump speed r/min   2700 2700 2700
Average injection quantity mm3/st.   24.6 21.1 28.1
Injection timing adjustment_04
Pump speed r/min   2600 2600 2600
Average injection quantity mm3/st.   26.8 24.7 28.9
Injection timing adjustment_05
Pump speed r/min   2500 2500 2500
Average injection quantity mm3/st.   26.8 24.8 28.8
Injection timing adjustment_06
Pump speed r/min   2000 2000 2000
Average injection quantity mm3/st.   28.6 26.6 30.6
Injection timing adjustment_07
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   30.2 29.2 31.2
Injection timing adjustment_08
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   28.8 26.8 30.8
Injection timing adjustment_09
Pump speed r/min   2965 2965 2965
Average injection quantity mm3/st.   11 11 11
Remarks
Measure with the angle beta (39~41degC) adjusted to within the specifications.
 
Injection timing adjustment_10
Pump speed r/min   2800 2650 2950
Average injection quantity mm3/st.   20.9 19.9 21.9
Basic   *
Remarks
Measure with the angle beta (39~41degC) adjusted to within the specifications.
 
Injection timing adjustment_11
Pump speed r/min   2700 2700 2700
Average injection quantity mm3/st.   24.6 21.1 28.1
Remarks
Measure with the angle beta (39~41degC) adjusted to within the specifications.
 
Injection timing adjustment_12
Pump speed r/min   2600 2600 2600
Average injection quantity mm3/st.   26.8 24.7 28.9
Remarks
Measure with the angle beta (39~41degC) adjusted to within the specifications.
 
Injection timing adjustment_13
Remarks
Measure with the angle beta (39~41degC) adjusted to within the specifications.
 
Injection quantity adjustment
Pump speed r/min   2965 2965 2965
Average injection quantity mm3/st.   11.1 10.1 12.1
Difference in delivery mm3/st.   3.5
Basic   *
Injection quantity adjustment_02
Pump speed r/min   2900 2900 2900
Average injection quantity mm3/st.   4.5
Remarks
Insert a 4.5+-0.1 mm shim between the C/L and the full speed position and measure injection quantity.
 
Governor adjustment
Pump speed r/min   425 425 425
Average injection quantity mm3/st.   6 5 7
Difference in delivery mm3/st.   2
Basic   *
Governor adjustment_02
Pump speed r/min   425 425 425
Average injection quantity mm3/st.   6 5 7
Governor adjustment_03
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   4
Governor adjustment_04
Pump speed r/min   1200 1200 1200
Average injection quantity mm3/st.   2
Timer adjustment
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   60 50 70
Basic   *
Speed control lever angle
Pump speed r/min   425 425 425
Average injection quantity mm3/st.   0 0 0
Remarks
Magnet OFF
 
0000000901
Pump speed r/min   1250 1250 1250
Overflow quantity cm3/min   370 240 500
Stop lever angle
Pump speed r/min   1250 1250 1250
Pressure kPa   362.5 343 382
Pressure kgf/cm2   3.7 3.5 3.9
Basic   *
Stop lever angle_02
Pump speed r/min   500 500 500
Pressure kPa   186.5 157 216
Pressure kgf/cm2   1.9 1.6 2.2
Stop lever angle_03
Pump speed r/min   1250 1250 1250
Pressure kPa   362.5 343 382
Pressure kgf/cm2   3.7 3.5 3.9
Stop lever angle_04
Pump speed r/min   2000 2000 2000
Pressure kPa   539.5 510 569
Pressure kgf/cm2   5.5 5.2 5.8
Stop lever angle_05
Pump speed r/min   2300 2300 2300
Pressure kPa   617.5 588 647
Pressure kgf/cm2   6.3 6 6.6
0000001101
Pump speed r/min   1250 1250 1250
Timer stroke mm   3.1 2.9 3.3
Basic   *
_02
Pump speed r/min   1250 1250 1250
Timer stroke mm   3.1 2.8 3.4
_03
Pump speed r/min   2000 2000 2000
Timer stroke mm   6.1 5.5 6.7
_04
Pump speed r/min   2300 2300 2300
Timer stroke mm   7.4 7 7.8
0000001201
Max. applied voltage V   8 8 8
Test voltage V   13 12 14
0000001401
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   18.1 17.6 18.6
Timer stroke variation dT mm   0.8 0.6 1
Basic   *
_02
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   18.1 17.1 19.1
Timer stroke variation dT mm   0.8 0.5 1.1
_03
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   7 5.5 8.5
Timer stroke variation dT mm   2.2 1.7 2.7
Timing setting
K dimension mm   3.3 3.2 3.4
KF dimension mm   5.8 5.7 5.9
MS dimension mm   1.6 1.5 1.7
Control lever angle alpha deg.   20 16 24
Control lever angle beta deg.   40 37 43

Test data Ex:

0000001801 V-FICD ADJUSTMENT

Test data 104748-1651
Adjustment of the V-FICD (perform with W-FICD released) 1. Adjust to obtain L1. 2. Confirm that L2 is obtained when negative pressure P1 (kPa) {P2 (mmHg)} is applied to the actuator. Adjust the stroke using the actuator stroke adjusting screw (F). (A): Pin (B): Actuator shaft (C): Control lever (D): Actuator (E): Lock nut (torque T)
----------
L1=1+1mm L2=1.45+-0.1mm P1=-53.3kPa P2=-400mmHg
----------
L1=1+1mm L2=1.45+-0.1mm T=1.2~1.5N-m{0.12~0.15kgf-m}

0000001901 W-CSD ADJUSTMENT

Test data 104748-1651
Adjustment of the W-CSD 1. Adjustment of the timer stroke Adjust screw (A) so that the timer stroke is the value determined from the graph (W) [(V), (W)]. 2. Adjustment of the position of the intermediate lever. Insert a shim L3 between the control lever (I) and the idle screw (G). Align the intermediate lever (F) with the aligning mark (J) and then fix the intermediate lever adjusting screw (E) so that (E) contacts the shim between (E) and (I). [(U), (V)] 3. Adjustment of the FICD Insert a shim L4 between the control lever (I) and the idle set screw (G). Use adjusting screw (B) to fix the CSD lever (C) in the position where it operates the intermediate lever (F) via the rod (D). [(U), (V), (W)] (O) Timer stroke adjustment (mm) (P): lever angle (deg) (Q): lever angle (deg) The (Q) indicates the clearance between the control lever and the idle set screw. X:Temperature t (deg C) Y1:Timer stroke TA (mm) Y2:Control lever position at theta L (deg, mm) (R): cooling water temperature (deg C) (S): cooling water temperature: increase direction N:Pump speed (M): timer piston stroke (mm) (K): colored ring (Z): lever position (mm)
----------
L3=1.2+-0.05mm L4=L3+-0.05mm
----------
L3=1.2+-0.05mm L4=L+-0.05mm L5=-mm R1=- R2=- M1=- M2=- K1=- K2=- Z1=- Z2=-




Information:


Location of Screwdriver While Holding BellcrankK. Rotate the timing position sensor bellcrank clock wise by inserting the No. 2 Phillips screwdriver between the arm of the bellcrank in contact with the timing position sensor until the screwdriver can be inserted into the hole in the cover to hold the bellcrank in position.
Hold Timing Position Sensor Bellcrank In PositionL. Install the gasket and timing advance housing (4).M. Remove the screwdriver to allow the bellcrank to contact the power piston.9. Check the timing sensor position calibration as described in P-531: Timing Position Sensor/Calibration.10. Install the timing solenoid (BTM). Make sure the arm of the timing solenoid is in the center groove of the control spool collar.11. Install the timing advance position sensor cover (3).P-540: Idle Shutdown Timer
System Operation
The idle shutdown timer is a feature which helps improve fuel consumption by limiting idling time. The timer may be programmed to shut down the idling engine after a period of time. This "shutdown time" is a customer specified parameter, and may be programmed for any period from 3 to 60 minutes. Programming the time to zero disables the idle shutdown timer.The timer is activated when the parking brake is set, vehicle speed is zero, and the engine is not under load. Ninety seconds before the programmed time is reached, the diagnostic lamp will begin to flash rapidly. If the driver moves the clutch pedal or brake pedal during this 90 second period, the timer will be overridden and is reset. A diagnostic code 71-00 will be set when the driver overrides the timer using the clutch or brake.If the timer is activated and allowed to shutdown the engine, then a code 71-01 will be set. Code 71-01 merely records the event and does not indicate a fault in PEEC III. If any of the codes for vehicle speed are Active, the idle shutdown timer will not operate.Diagnostic Codes
Functional Test
P-541: Multi-Torque
System Operation
Multi-Torque is an optional feature available with certain PEEC III engines. The feature is available only in certain personality modules.The 310 Multi-Torque provides an otherwise standard 310 hp PEEC III engine with two different torque curves. In all gears except top gear, the engine performs as a standard 310 hp PEEC III. In top gear, however, the engine is provided with the torque of a standard 310 hp at 1800 rpm, but with the peak torque of 350 hp at 1150 rpm (see the following illustrations).PEEC III determines whether the vehicle is in top gear by sensing the ratio of engine speed to vehicle speed. If the ratio of engine speed/vehicle speed is less than 26.6, the engine will perform like a standard 310 hp PEEC III.The 350 Multi-Torque works just like the 310Multi-Torque, except for two key differences. First, the multi-torque curve provides the engine with the standard 350 hp torque at 1800 rpm, and with the peak torque of a 400 hp at 1200 rpm (see the following illustration). Second, the multi-torque is in effect in the top two gears,

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