104749-6020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047496020 8941433310

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104749-6020 1047496020

ISUZU 8941433310 8941433310

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Cross reference number

ZEXEL 104749-6020 1047496020

ISUZU 8941433310 8941433310

Zexel num

Bosch num

Firm num

Name

104749-6020
104749-6021

8941433310 ISUZU

INJECTION-PUMP ASSEMBLY
4FC1-D *

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. 33.3 32.8 33.8

Difference in delivery mm3/st. 2.5

Basic *

Injection timing adjustment_02

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 15.6 13.6 17.6

Injection timing adjustment_03

Pump speed r/min 2250 2250 2250

Average injection quantity mm3/st. 32.25 30.1 34.4

Injection timing adjustment_04

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 33.3 32.3 34.3

Injection timing adjustment_05

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 27.1 25.1 29.1

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 32.5 32 33

Difference in delivery mm3/st. 2.5

Basic *

Remarks
For Japan

Injection timing adjustment_07

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 15.2 13.2 17.2

Remarks
For Japan

Injection timing adjustment_08

Pump speed r/min 2250 2250 2250

Average injection quantity mm3/st. 31.5 29.4 33.6

Remarks
For Japan

Injection timing adjustment_09

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 32.5 31.5 33.5

Remarks
For Japan

Injection timing adjustment_10

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 26.5 24.5 28.5

Remarks
For Japan

Injection quantity adjustment

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 15.9 14.9 16.9

Basic *

Injection quantity adjustment_02

Pump speed r/min 2900 2900 2900

Average injection quantity mm3/st. 5.1

Injection quantity adjustment_03

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 15.5 14.5 16.5

Basic *

Remarks
For Japan

Injection quantity adjustment_04

Pump speed r/min 2900 2900 2900

Average injection quantity mm3/st. 5

Remarks
For Japan

Governor adjustment

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 7.75 5.7 9.8

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 7.75 5.7 9.8

Governor adjustment_03

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 0 0 0

Governor adjustment_04

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 7.6 5.6 9.6

Difference in delivery mm3/st. 2

Basic *

Remarks
For Japan

Governor adjustment_05

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 7.6 5.6 9.6

Remarks
For Japan

Governor adjustment_06

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 0 0 0

Remarks
For Japan

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 64 54 74

Basic *

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 62 52 72

Basic *

Remarks
For Japan

Speed control lever angle

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

Speed control lever angle_02

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 0 0 0

Remarks
For Japan: Magnet OFF

0000000901

Pump speed r/min 1250 1250 1250

Overflow quantity cm3/min 456 324 588

_02

Pump speed r/min 1250 1250 1250

Overflow quantity cm3/min 480 348 612

Remarks
For Japan

Stop lever angle

Pump speed r/min 1250 1250 1250

Pressure kPa 480.5 461 500

Pressure kgf/cm2 4.9 4.7 5.1

Basic *

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Pressure kPa 480.5 461 500

Pressure kgf/cm2 4.9 4.7 5.1

Stop lever angle_03

Pump speed r/min 2000 2000 2000

Pressure kPa 647.5 618 677

Pressure kgf/cm2 6.6 6.3 6.9

Stop lever angle_04

Pump speed r/min 1250 1250 1250

Pressure kPa 470.5 451 490

Pressure kgf/cm2 4.8 4.6 5

Basic *

Remarks
For Japan

Stop lever angle_05

Pump speed r/min 1250 1250 1250

Pressure kPa 470.5 451 490

Pressure kgf/cm2 4.8 4.6 5

Remarks
For Japan

Stop lever angle_06

Pump speed r/min 2000 2000 2000

Pressure kPa 637.5 608 667

Pressure kgf/cm2 6.5 6.2 6.8

Remarks
For Japan

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke mm 4 3.8 4.2

Basic *

_02

Pump speed r/min 1250 1250 1250

Timer stroke mm 4 3.7 4.3

_03

Pump speed r/min 1800 1800 1800

Timer stroke mm 6.9 6.3 7.5

_04

Pump speed r/min 2250 2250 2250

Timer stroke mm 9.1 8.8 9.4

_05

Pump speed r/min 1250 1250 1250

Timer stroke mm 3.9 3.7 4.1

Basic *

Remarks
For Japan

_06

Pump speed r/min 1250 1250 1250

Timer stroke mm 3.9 3.6 4.2

Remarks
For Japan

_07

Pump speed r/min 1800 1800 1800

Timer stroke mm 6.7 6.1 7.3

Remarks
For Japan

_08

Pump speed r/min 2250 2250 2250

Timer stroke mm 9 8.6 9.4

Remarks
For Japan

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

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

Pre-stroke mm 0.25 0.23 0.27

Control lever angle alpha deg. -3 -7 1

Control lever angle beta deg. 37 32 42

Information:

Putting cylinder head gasket6. Cylinder head installation Put the cylinder head in position on the cylinder block, making sure the guide bolts are all in alignment with their respective bolt holes in the head.
Installing cylinder head7. Cylinder head bolt tightening (1) Remove the guide bolts and install the bolts that hold the cylinder head to the cylinder block. (2) Tighten the bolts in the number sequence in two or three steps to the specified torque.
Tightening sequence8. Valve push rod installation (1) Put the valve push rod into position through the bore in the cylinder head.(2) Make sure the ball end of the push rod has been put into position over the top of the tappet.
Installing valve push rods9. Rocker shaft assembling (1) Install the rocker arms, brackets and springs on the rocker shaft. Secure the brackets to the shaft by tightening the bolts.(2) Make sure the rocker arms move freely.
Assembling rocker arms10. Rocker shaft assembly installation(1) Install the valve caps in position on the top of the valves. (2) Put the rocker shaft assembly in position on the cylinder head. Tighten the bolts that hold the rocker shaft assembly to the specified torque.
Installing rocker shaft assembly11. Valve clearance adjustment Make reference to "VALVE CLEARANCE" (page 159).
Adjusting valve clearance12. Rocker cover installation (1) Make sure the gasket is put on the rocker cover.(2) Tighten the bolts that hold the rocker cover to the specified torque.
Installing rocker coverAIR INLET SYSTEM AND EXHAUST SYSTEM
1. Air inlet cover installation Tighten the bolts that hold the air inlet cover to the specified torque. 2. Exhaust manifold installation Tighten the bolts that hold the exhaust manifold to the specified torque. FUEL SYSTEM
1. Fuel injection nozzle installation (1) Put the gasket on the nozzle. (2) Put the nozzle assembly in position in the cylinder head and tighten