104741-6351 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047416351 8943268702

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104741-6351 1047416351

ISUZU 8943268702 8943268702

Cross reference number

ZEXEL 104741-6351 1047416351

ISUZU 8943268702 8943268702

Zexel num

Bosch num

Firm num

Name

104741-6351
104741-6352

8943268702 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1-TC *

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 157805-7320

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 1250 1250 1250

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 68.6 68.1 69.1

Difference in delivery mm3/st. 3.5

Basic *

Remarks
Full

Injection timing adjustment_02

Pump speed r/min 800 800 800

Boost pressure kPa 40.65 39.3 42

Boost pressure mmHg 305 295 315

Average injection quantity mm3/st. 48.2 47.7 48.7

Difference in delivery mm3/st. 4.5

Basic *

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 2300 2300 2300

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 19.6 16.1 23.1

Injection timing adjustment_04

Pump speed r/min 1900 1900 1900

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 71 66.5 75.5

Injection timing adjustment_05

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 51.1 47.6 54.6

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 68.6 67.6 69.6

Injection timing adjustment_07

Pump speed r/min 800 800 800

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 305 295 315

Average injection quantity mm3/st. 48.2 47.2 49.2

Injection timing adjustment_08

Pump speed r/min 600 600 600

Boost pressure kPa 18.65 17.3 20

Boost pressure mmHg 140 130 150

Average injection quantity mm3/st. 37.7 34.7 40.7

Injection timing adjustment_09

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 42 36.5 47.5

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 19.6 16.6 22.6

Difference in delivery mm3/st. 4.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2400 2400 2400

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 12

Governor adjustment

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 8.1 6.1 10.1

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 8.1 6.1 10.1

Governor adjustment_03

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

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. 85 80 90

Basic *

Speed control lever angle

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1500 1500 1500

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Overflow quantity with S/T ON cm3/min 471 342 600

Overflow quantity with S/T OFF cm3/min 519 390 648

Stop lever angle

Pump speed r/min 1500 1500 1500

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure kPa 480.5 461 500

Pressure kgf/cm2 4.9 4.7 5.1

Basic *

Stop lever angle_02

Pump speed r/min 1500 1500 1500

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 480.5 461 500

Pressure with S/T OFF kgf/cm2 4.9 4.7 5.1

Stop lever angle_03

Pump speed r/min 1900 1900 1900

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 598.5 569 628

Pressure with S/T OFF kgf/cm2 6.1 5.8 6.4

0000001101

Pump speed r/min 1500 1500 1500

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke mm 5.1 4.9 5.3

Basic *

_02

Pump speed r/min 1500 1500 1500

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke with S/T OFF mm 5.1 4.9 5.3

_03

Pump speed r/min 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke with S/T OFF mm 7.1 6.7 7.5

_04

Pump speed r/min 1900 1900 1900

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke with S/T OFF mm 8.65 8.3 9

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 2.8 2.7 2.9

KF dimension mm 5.5 5.4 5.6

MS dimension mm 1 0.9 1.1

BCS stroke mm 3.9 3.8 4

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 24 20 28

Control lever angle beta deg. 48 43 53

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjusting method [applied voltage Vi, dummy bolt (C)] 1. Hold the dummy bolt (C) against the control lever at position N = N1, Q = Q1. Fix using the lock nut. 2. When adjusting the potentiometer, position the control lever against the dummy bolt (C) and adjust the potentiometer so that the output voltage is V1 (V). 3. Remove the dummy bolt (C) after the completion of adjustment. Confirm that the potentiometer output voltage is within the above mentioned standards between the control lever's adjusting point and the idling position. N:Pump speed V:Output voltage Q:Injection quantity P:Boost pressure A:Adjusting point B:Checking point Q2:Idle Q3:Full speed (C): Dummy bolt (D): Bracket for mounting the dummy bolt
----------
N1=750r/min V1=2.49+-0.03V Q1=8.7+-1cm3/1,000st Vi=10V
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N1=750r/min N2=385r/min V1=2.49+-0.03V V2=0.96+-0.4V V3=-V Q1=8.7+-1cm3/1,000st Q2=8.1+-2cm3/1,000st Idle Q3=-cm3/1,000st P1=80.0kPa P2=600mmHg

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Adjust the actuator rod to obtain S1. 2. Apply negative pressure P1 kPa {P2 mmHg} to the actuator and confirm that it moves through its full stroke. (A) Control lever (Idling position)
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S1=1+1mm P1=-53.3kPa P2=-400mmHg
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0000002001 MICROSWITCH ADJUSTMENT

Microswitch adjustment 1. Insert a shim L between the control lever and the idling stopper bolt. 2. At pump speed N1 and boost pressure P1 {P2}, adjust the injection quantity to Q1. 3. Insert a shim L between the control lever and the idling stopper bolt and move the microswitch in the direction of the arrow until it turns ON. 4. Remove the shim and confirm that the potentiometer turns from ON to OFF within the potentiometer output range V1. (A): microswitch fixing bolt
----------
N1=1000r/min Q1=29.1+-7cm3/1,000st P1=80.0kPa P2=600mmHg L=8.7mm V1=2.49+-0.03V
----------
T=2~3N-m{0.2~0.3kgf-m} L=8.7mm

0000002101 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).
----------

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L=3~6mm T=3.4~4.9N-m(0.35~0.5kgf-m)