104748-1690 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047481690

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104748-1690 1047481690

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Cross reference number

ZEXEL 104748-1690 1047481690

Zexel num

Bosch num

Firm num

Name

104748-1690
104748-1691

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. 31.2 30.7 31.7

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 7.6 14.6

Injection timing adjustment_03

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 25.3 21.8 28.8

Injection timing adjustment_04

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 26.9 24.8 29

Injection timing adjustment_05

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 27 25 29

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 31.2 30.2 32.2

Injection timing adjustment_07

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 29.7 27.7 31.7

Injection quantity adjustment

Pump speed r/min 2965 2965 2965

Average injection quantity mm3/st. 11.1 8.1 14.1

Difference in delivery mm3/st. 3.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2900 2900 2900

Average injection quantity mm3/st. 3

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 375 375 375

Average injection quantity mm3/st. 6 4 8

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 6 4 8

Governor adjustment_03

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 2

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50 50

Basic *

Speed control lever angle

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1250 1250 1250

Overflow quantity cm3/min 369 240 498

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 620 520 720

Timer stroke mm 0.5 0.5 0.5

_03

Pump speed r/min 1250 1250 1250

Timer stroke mm 3.1 2.8 3.4

_04

Pump speed r/min 2000 2000 2000

Timer stroke mm 6.1 5.5 6.7

_05

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. 22.1 21.6 22.6

Timer stroke variation dT mm 0.8 0.6 1

Basic *

_02

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 22.1 21.1 23.1

Timer stroke variation dT mm 0.8 0.4 1.2

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. 45 40 50

Test data Ex:

0000001801 V-FICD ADJUSTMENT

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=1.6+-0.1mm P1=-46.7kPa P2=-350mmHg
----------
L1=1+1mm L2=1.6+-0.1mm T=1.2~1.5N-m{0.12~0.15kgf-m}

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the timer stroke Adjust using screw (A) so that the timer stroke is the value determined using the graph (W). [(K), (M)] 2. Adjustment of the position of the intermediate lever. With a shim L5 inserted between the control lever (I) and the FICD set screw (E), insert a shim (L3) between (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 the 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)] However, set with a shim L5 inserted. [(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 L5=-mm
----------
L3=1.2+-0.05mm L5=-mm R1=-degC R2=-degC M1=-mm M2=-mm K1=-deg K2=-deg Z1=-mm Z2=-mm

Information:

(1) Thickness of spacer plate ... 8.585 0.025 mm (.3379 .0009 in)Thickness of gasket that is placed between spacer plate and cylinder block ... 0.208 0.025 mm (.0081 .0009 in)Height of liner over spacer plate, under installation pressure ... 0.13 0.08 mm (.005 .003 in)(2) Height of four dowels above top surface of cylinder block:End dowels (Put 7M7456 Bearing Mount Compound on two end dowels at installation) ... 18.5 0.5 mm (.73 .02 in)Middle dowels ... 16.0 0.5 mm (.63 .02 in)(3) Dimension (new) from centerline of crankshaft bearing bore to top of block (top deck) ... 425.45 0.15 mm (16.750 .006 in)Minimum dimension from centerline of crankshaft bearing bore to top of block (top deck) ... 425.02 mm (16.733 in) The flatness across the whole contact surface of the block must be within 0.10 mm (.004 in) and within 0.05 mm (.002 in) for any 177 mm (7.0 in) section of the surface. The surface finish specification is 3.2 micrometers (125 micro-inches) maximum.(4) Bore in block for camshaft bearings ... 76.835 0.018 mm (3.0250 .0007 in) Install bearings with the oil holes in the bearings on the horizontal centerline. Make sure the bearing joint position is above the oil holes.(5) Bore in the block for the main bearings:Standard, original size (new) ... 129.891 0.013 mm (5.1138 .0005 in)0.64 mm (.025 in) larger than original size ... 130.526 0.013 mm (5.1388 .0005 in)(6) Distance from front of rear face of cylinder block to end of dowels ... 19.1 0.05 mm (.75 .02 in)(7) Width of main bearing cap ... 215.900 0.013 mm (8.5000 .0005 in)Width of block for main bearing cap ... 215.900 0.013 mm (8.5000 .0005 in)Clearance between main bearing cap and cylinder block ... 0.025 mm (.0009 in) tight to ... 0.025 mm (.0009 in) loose
Tightening Procedure For Main Bearings(8) Torque for the bolts that hold the caps for the main bearings: Install the main bearing caps with the marks (arrow) toward the front of the engine. Install each cap in the correct position by putting the number stamped on the bottom of the cap toward the corresponding number cast on left side of the cylinder block at the pan rail.a. Put 2P2506 Thread Lubricant on the threads of the bolts.b. Tighten the bolts first on the bearing tab side of the cap to ... 260 14 N m (190 10 lb ft)c. Tighten the bolts on the opposite side to ... 260 14 N m (190 10 lb ft)d. Put a mark on each bolt and cap.e. Tighten the bolts on the opposite side, from the mark ... 120 5°f. Tighten the bolts on the bearing tab side of the cap, from the mark ... 120 5°(9) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 165.10 0.10