104746-5460 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047465460 8973503960

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104746-5460 1047465460

ISUZU 8973503960 8973503960

Cross reference number

ZEXEL 104746-5460 1047465460

ISUZU 8973503960 8973503960

Zexel num

Bosch num

Firm num

Name

104746-5460
104746-5461

8973503960 ISUZU

INJECTION-PUMP ASSEMBLY
4JA1-L * K

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)
Left L

(Solenoid timer adjustment condition)
OFF OFF

Timer measuring device installation position
Low pressure side LOW PRESSURE SIDE

Injection timing adjustment

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 72.7 72.2 73.2

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 54.8 49.3 60.3

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 64.5 59 70

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 71.4 65.9 76.9

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 72.7 71.7 73.7

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1900 1900 1900

Average injection quantity mm3/st. 83.9 79.4 88.4

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 28.4 25.4 31.4

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 28.4 25.4 31.4

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 10.6 8.6 12.6

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 10.6 8.6 12.6

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 70 110

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 70 110

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1600 1600 1600

Overflow quantity with S/T ON cm3/min 1120 890 1350

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1600 1600 1600

Pressure with S/T ON kPa 667 628 706

Pressure with S/T ON kgf/cm2 6.8 6.4 7.2

Pressure with S/T OFF kPa 598 578 618

Pressure with S/T OFF kgf/cm2 6.1 5.9 6.3

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_02

Pump speed r/min 1300 1300 1300

Pressure with S/T ON kPa 569 520 618

Pressure with S/T ON kgf/cm2 5.8 5.3 6.3

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1500 1500 1500

Pressure with S/T OFF kPa 569 540 598

Pressure with S/T OFF kgf/cm2 5.8 5.5 6.1

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1600 1600 1600

Pressure with S/T ON kPa 667 628 706

Pressure with S/T ON kgf/cm2 6.8 6.4 7.2

Pressure with S/T OFF kPa 598 578 618

Pressure with S/T OFF kgf/cm2 6.1 5.9 6.3

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_05

Pump speed r/min 1900 1900 1900

Pressure with S/T OFF kPa 696 667 725

Pressure with S/T OFF kgf/cm2 7.1 6.8 7.4

Oil temperature degC 50 48 52

Stop lever angle_06

Pump speed r/min 2200 2200 2200

Pressure with S/T OFF kPa 824 765 883

Pressure with S/T OFF kgf/cm2 8.4 7.8 9

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1600 1600 1600

Timer stroke with S/T ON mm 4.1 3.7 4.5

Timer stroke with S/T OFF mm 2.5 2.3 2.7

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 1300 1300 1300

Timer stroke with S/T ON mm 1.7 1.2 2.2

Oil temperature degC 50 48 52

_03

Pump speed r/min 1600 1600 1600

Timer stroke with S/T ON mm 4.1 3.6 4.6

Timer stroke with S/T OFF mm 2.5 2.3 2.7

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_04

Pump speed r/min 1800 1800 1800

Timer stroke with S/T OFF mm 4.1 3.7 4.5

Oil temperature degC 50 48 52

_05

Pump speed r/min 2200 2200 2200

Timer stroke with S/T OFF mm 4.8 4.5 5.2

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 3.6 3.5 3.7

KF dimension mm 7.7 7.6 7.8

MS dimension mm 0.8 0.7 0.9

Pre-stroke mm 0.2 0.18 0.22

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 37 32 42

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjusting method (applied voltage Vi, dummy bolt method) 1. Hold the dummy bolt against the control lever at position N = N1 and Q = Q1 and fix using the lock nut. 2. At potentiometer adjustment, with the control lever contacting the dummy bolt, adjust the potentiometer so that the output voltage is V1. 3. After completing adjustment remove the dummy bolt. Confirm that the potentiometer output voltage is as specified above at the control lever idle position and full position. N:Pump speed Q:Injection quantity V:Output voltage A:Adjusting point B:Checking point I:Idle F:Full speed (C) Corresponding to dummy bolt 146526-3300 (D) Corresponding to nut 013020-6040 (E) Dummy bolt installation bracket
----------
N1=1420r/min Q1=26.2+-1.0mm3/st V1=4.33+-0.03V Vi=10V
----------
N1=1420r/min Q1=26.2+-1.0mm3/st V1=4.33+-0.03V V2=(1.53+-0.61V) V3=7.70+-0.72V

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Confirm that the clearance between the V-FICD control lever (B) and the actuator rod (A) is at least L2. 2. Insert a shim L1 between the control lever (D) and the idle set screw (C). 3. Adjust the stroke adjusting screw (E) so that the actuator moves through its full stroke. Then, fix using nut (F). 4. When adjustment using stroke adjusting screw (E) is not possible, move the actuator rod position using (G), (H) and (I) and adjust the stroke using (E) and (F). 5. Apply negative pressure P1 to the actuator and confirm the full stroke. 6. After releasing negative pressure, re-confirm that the clearance between (A) and (B) is at least L2.
----------
L1=0.7+-0.1mm L2=1.0mm P1=-53.3kPa(-400mmHg)
----------
L1=0.7+-0.1mm L2=1.0++mm T1=1.4~2.0N-m(0.14~0.20kgf-m) T2=3.4~4.9N-m(0.35~0.50kgf-m)