104749-5161 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047495161 8970374940

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104749-5161 1047495161

ISUZU 8970374940 8970374940

Cross reference number

ZEXEL 104749-5161 1047495161

ISUZU 8970374940 8970374940

Zexel num

Bosch num

Firm num

Name

104749-5161
104749-5162

8970374940 ISUZU

INJECTION-PUMP ASSEMBLY
4EE1TC 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)
Right R

Injection timing adjustment

Pump speed r/min 900 900 900

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 47.4 46.9 47.9

Difference in delivery mm3/st. 3.5

Basic *

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 52.3 51.8 52.8

Difference in delivery mm3/st. 3.5

Basic *

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 2750 2750 2750

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 24.4 20.9 27.9

Injection timing adjustment_04

Pump speed r/min 2250 2250 2250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 50.9 47.9 53.9

Injection timing adjustment_05

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 52.3 51.3 53.3

Remarks
Full

Injection timing adjustment_06

Pump speed r/min 1500 1500 1500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 37.4 34.9 39.9

Injection timing adjustment_07

Pump speed r/min 900 900 900

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 47.4 46.4 48.4

Remarks
CBS

Injection timing adjustment_08

Pump speed r/min 750 750 750

Boost pressure kPa 32 30.7 33.3

Boost pressure mmHg 240 230 250

Average injection quantity mm3/st. 46.9 44.4 49.4

Injection timing adjustment_09

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 39.6 36.6 42.6

Injection quantity adjustment

Pump speed r/min 2750 2750 2750

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 24.4 21.4 27.4

Difference in delivery mm3/st. 5.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2950 2950 2950

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 4

Remarks
Insert a 1 mm shim between the control lever and the full speed position and measure the injection quantity.

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. 8.9 6.9 10.9

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

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

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. 8.9 6.9 10.9

Timer adjustment

Pump speed r/min 150 150 150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 35 25 45

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

0000000901

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 330 198 462

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Overflow quantity cm3/min 630 498 762

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure kPa 411.5 392 431

Pressure kgf/cm2 4.2 4 4.4

Basic *

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure kPa 411.5 392 431

Pressure kgf/cm2 4.2 4 4.4

Stop lever angle_03

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure kPa 480.5 451 510

Pressure kgf/cm2 4.9 4.6 5.2

Stop lever angle_04

Pump speed r/min 2000 2000 2000

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure kPa 598.5 569 628

Pressure kgf/cm2 6.1 5.8 6.4

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 4.7 4.5 4.9

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 4.7 4.4 5

_03

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 6.4 5.8 7

_04

Pump speed r/min 2000 2000 2000

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 9 8.6 9.4

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 38.3 37.3 39.3

Timer stroke variation dT mm 0.9 0.7 1.1

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 38.3 36.8 39.8

Timer stroke variation dT mm 0.9 0.6 1.2

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 28.6 27.1 30.1

Timer stroke variation dT mm 2 1.5 2.5

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 0.9 0.8 1

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=1.32+-0.1mm P1=-46.7kPa P2=-350mmHg
----------
L1=1+1mm L2=1.32+-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 screw (A) so that the timer stroke is the value determined from the graph. 2. Adjustment of the position of the intermediate lever. Insert a shim L between the control lever I and the idle setscrew G. Align the intermediate lever (F) with the aligning line and fix screw intermediate lever's adjusting (E) so that it contacts the control lever. 3. Adjustment of the FICD Insert a shim LT between the control lever I and the idle setscrew G. Use adjusting screw (B) to fix the CSD lever (C) in the position where it operates the intermediate lever via the rod (D). (J) Aligning mark (O) = timer stroke adjustment (mm): TA = -0.041t+2.42 (P) Lever position (deg): theta 1 = -0.108t+4.79 (-20 deg C <= t <= 20 deg C) Theta 2 = -0.133t + 5.29 (20 deg C =< t =< 50 deg C) (Q) Lever position (mm): L1 = -0.035t+1.57 (-20 deg C <= t <= 20 deg C) L2 = -0.044t + 1.75 (20 deg C =< t =< 50 deg C) 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 (r/min) (M) Timer piston stroke (mm) (K) Lever angle (deg) (Z) Lever position (mm)
----------
L=1.2+-0.05mm LT=L+-0.05mm
----------
L=1.2+-0.05mm N1=500r/min R1=20degC R2=-20degC M1=1.9+-0.4mm M2=3.4+-0.6mm K1=3.6+-1deg K2=7.9+-3deg Z1=1.2+-0.3mm Z2=2.6+-1mm