Information injection-pump assembly
ZEXEL
104749-6871
1047496871
ISUZU
8944593781
8944593781
Rating:
Cross reference number
ZEXEL
104749-6871
1047496871
ISUZU
8944593781
8944593781
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
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
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
Right R
Injection timing adjustment
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
40
38.7
41.3
Boost pressure
mmHg
300
290
310
Average injection quantity
mm3/st.
31.6
31.1
32.1
Difference in delivery
mm3/st.
2.5
Basic
*
Remarks
Full
Full
Injection timing adjustment_02
Pump speed
r/min
700
700
700
Boost pressure
kPa
16
14.7
17.3
Boost pressure
mmHg
120
110
130
Average injection quantity
mm3/st.
28.2
27.7
28.7
Basic
*
Remarks
CBS
CBS
Injection timing adjustment_03
Pump speed
r/min
1500
1500
1500
Boost pressure
kPa
40
38.7
41.3
Boost pressure
mmHg
300
290
310
Average injection quantity
mm3/st.
7.7
4.2
11.2
Injection timing adjustment_04
Pump speed
r/min
1400
1400
1400
Boost pressure
kPa
40
38.7
41.3
Boost pressure
mmHg
300
290
310
Average injection quantity
mm3/st.
33.2
29.7
36.7
Injection timing adjustment_05
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
40
38.7
41.3
Boost pressure
mmHg
300
290
310
Average injection quantity
mm3/st.
31.6
30.6
32.6
Injection timing adjustment_06
Pump speed
r/min
700
700
700
Boost pressure
kPa
16
14.7
17.3
Boost pressure
mmHg
120
110
130
Average injection quantity
mm3/st.
28.2
27.2
29.2
Injection timing adjustment_07
Pump speed
r/min
600
600
600
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
26.1
23.6
28.6
Injection quantity adjustment
Pump speed
r/min
1500
1500
1500
Boost pressure
kPa
40
38.7
41.3
Boost pressure
mmHg
300
290
310
Average injection quantity
mm3/st.
7.7
4.7
10.7
Difference in delivery
mm3/st.
3
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
1550
1550
1550
Boost pressure
kPa
40
38.7
41.3
Boost pressure
mmHg
300
290
310
Average injection quantity
mm3/st.
3
Governor adjustment
Pump speed
r/min
375
375
375
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
6.8
4.8
8.8
Difference in delivery
mm3/st.
2
Basic
*
Governor adjustment_02
Pump speed
r/min
425
425
425
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
2
Governor adjustment_03
Pump speed
r/min
375
375
375
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
6.8
4.8
8.8
Governor adjustment_04
Pump speed
r/min
300
300
300
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
34.4
27.9
40.9
Timer adjustment
Pump speed
r/min
100
100
100
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
40
36.5
43.5
Basic
*
Speed control lever angle
Pump speed
r/min
375
375
375
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF
Magnet OFF
0000000901
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Overflow quantity
cm3/min
360
228
492
Stop lever angle
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Pressure
kPa
392.5
373
412
Pressure
kgf/cm2
4
3.8
4.2
Basic
*
Stop lever angle_02
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Pressure
kPa
392.5
373
412
Pressure
kgf/cm2
4
3.8
4.2
Stop lever angle_03
Pump speed
r/min
1400
1400
1400
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Pressure
kPa
500.5
471
530
Pressure
kgf/cm2
5.1
4.8
5.4
0000001101
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Timer stroke
mm
1.1
0.9
1.3
Basic
*
_02
Pump speed
r/min
850
850
850
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Timer stroke
mm
0.8
_03
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Timer stroke
mm
1.1
0.8
1.4
_04
Pump speed
r/min
1400
1400
1400
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Timer stroke
mm
2.9
2.3
3.5
_05
Pump speed
r/min
1500
1500
1500
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Timer stroke
mm
3.3
2.9
3.7
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
1.8
1.7
1.9
BCS stroke
mm
1.4
1.3
1.5
Control lever angle alpha
deg.
25
21
29
Control lever angle beta
deg.
46.5
41.5
51.5
Test data Ex:
0000001801 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).
(C) = stopper bolt
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L=2~8.5mm
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L=2~8.5mm
Information:
Reversal of Crankcase
Gently lay the crankcase on its side, then turn the crankcase upside down.
Resting the crankcase with the oil pan on the bottom can cause the oil pan to crack.
Reversal of crankcaseRemoval of Oil Pan And Oil Pan Gasket
(1) Unscrew the oil pan mounting bolts, and detach the oil pan.(2) Remove the oil pan gasket.
Removal of oil pan and oil gasketRemoval of Oil Pump
Unscrew the oil pump set bolt, and pull out the oil pump.
Removal of oil pumpRemoval of Camshaft
(1) Position the camshaft gear so that the two lightening holes are on the top and bottom, then remove the thrust plate mounting bolts using the socket. (2) Pull out the camshaft from the crankcase.
Removal of camshaft
Be careful not to damage the cams and bearing sections on the camshaft.
Removal of Front Plate
Unscrew the front plate mounting bolts, and dismount the front plate (together with the injection pump) from the crankcase.
Removal of front platePistons, Connecting Rods, Crankshaft and Crankcase
When replacing the crankcase, remove all accessories (relief valve and others) carefully from the crankcase, and reinstall them on a new crankcase.Laying Crankcase on Its Side
Gently lay the crankcase on its side.
Laying crankcase on its sideMeasurement of Thrust Clearance on Big-End of Connecting Rod
(1) Measure the clearance between the big-end of each connecting rod and the crankshaft (end play) with feeler gages. (2) If the measured clearance exceeds the limit value, replace the connecting rod.
Measurement of thrust clearance on big-end of connecting rodWeight Difference Among Connecting Rod Assemblies
When replacing connecting rods, make sure that all connecting rods have the same weight rank mark.
Weight rank mark on connecting rodRemoval of Connecting Rod Caps
(1) On each connecting rod and cap, put a mark indicating its cylinder No.(2) Remove the connecting rod caps.(3) For each removed connecting rod bearing (lower half), indicate the piston No. from which it was removed and the upper/lower identification. Be careful not to damage the bearings. Arrange the removed bearings in such a way that they can be reinstalled in their original positions during reassembly.
Removal of connecting rod capPreparation For Removal of Pistons
If carbon deposits are present at the upper sections of the cylinders, remove the carbon deposits with sandpaper and a cloth to facilitate piston removal.
Preparation for removal of pistonRemoval of Pistons
(1) Turn the crankshaft to bring the piston to be removed to the top dead center.(2) Using the wooden handle of a hammer, push the connecting rod on the cap contacting surface to remove the piston and connecting rod assembly from the top side of the cylinder.
Removal of pistonRemoval of Piston Ring
Using the piston ring pliers, remove the piston rings
Removal of piston ringRemoval of Piston Pins
Removal of piston pin(1) Using the snap ring pliers, remove the snap rings.(2) Pull out the piston pin, and separate the piston from the connecting rod.(3) If the piston pin cannot be remove easily, heat the piston with a piston heater or in hot water.Reversal of Crankcase
Gently stand the crankcase so that the oil pan mounting side faces up.
Reversal of crankcaseMeasurement of
Gently lay the crankcase on its side, then turn the crankcase upside down.
Resting the crankcase with the oil pan on the bottom can cause the oil pan to crack.
Reversal of crankcaseRemoval of Oil Pan And Oil Pan Gasket
(1) Unscrew the oil pan mounting bolts, and detach the oil pan.(2) Remove the oil pan gasket.
Removal of oil pan and oil gasketRemoval of Oil Pump
Unscrew the oil pump set bolt, and pull out the oil pump.
Removal of oil pumpRemoval of Camshaft
(1) Position the camshaft gear so that the two lightening holes are on the top and bottom, then remove the thrust plate mounting bolts using the socket. (2) Pull out the camshaft from the crankcase.
Removal of camshaft
Be careful not to damage the cams and bearing sections on the camshaft.
Removal of Front Plate
Unscrew the front plate mounting bolts, and dismount the front plate (together with the injection pump) from the crankcase.
Removal of front platePistons, Connecting Rods, Crankshaft and Crankcase
When replacing the crankcase, remove all accessories (relief valve and others) carefully from the crankcase, and reinstall them on a new crankcase.Laying Crankcase on Its Side
Gently lay the crankcase on its side.
Laying crankcase on its sideMeasurement of Thrust Clearance on Big-End of Connecting Rod
(1) Measure the clearance between the big-end of each connecting rod and the crankshaft (end play) with feeler gages. (2) If the measured clearance exceeds the limit value, replace the connecting rod.
Measurement of thrust clearance on big-end of connecting rodWeight Difference Among Connecting Rod Assemblies
When replacing connecting rods, make sure that all connecting rods have the same weight rank mark.
Weight rank mark on connecting rodRemoval of Connecting Rod Caps
(1) On each connecting rod and cap, put a mark indicating its cylinder No.(2) Remove the connecting rod caps.(3) For each removed connecting rod bearing (lower half), indicate the piston No. from which it was removed and the upper/lower identification. Be careful not to damage the bearings. Arrange the removed bearings in such a way that they can be reinstalled in their original positions during reassembly.
Removal of connecting rod capPreparation For Removal of Pistons
If carbon deposits are present at the upper sections of the cylinders, remove the carbon deposits with sandpaper and a cloth to facilitate piston removal.
Preparation for removal of pistonRemoval of Pistons
(1) Turn the crankshaft to bring the piston to be removed to the top dead center.(2) Using the wooden handle of a hammer, push the connecting rod on the cap contacting surface to remove the piston and connecting rod assembly from the top side of the cylinder.
Removal of pistonRemoval of Piston Ring
Using the piston ring pliers, remove the piston rings
Removal of piston ringRemoval of Piston Pins
Removal of piston pin(1) Using the snap ring pliers, remove the snap rings.(2) Pull out the piston pin, and separate the piston from the connecting rod.(3) If the piston pin cannot be remove easily, heat the piston with a piston heater or in hot water.Reversal of Crankcase
Gently stand the crankcase so that the oil pan mounting side faces up.
Reversal of crankcaseMeasurement of