104749-6170 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047496170 8941782620

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104749-6170 1047496170

ISUZU 8941782620 8941782620

Cross reference number

ZEXEL 104749-6170 1047496170

ISUZU 8941782620 8941782620

Zexel num

Bosch num

Firm num

Name

104749-6170

8941782620 ISUZU

INJECTION-PUMP ASSEMBLY
4FC1J *

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. 38.1 37.6 38.6

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 36.6 35.1 38.1

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 38.1 37.1 39.1

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2000 2000 2000

Average injection quantity mm3/st. 34.1 32.6 35.6

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 34.5 32.9 36.1

Difference in delivery mm3/st. 4.5

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2650 2650 2650

Average injection quantity mm3/st. 11 8 14

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2650 2650 2650

Average injection quantity mm3/st. 11 8 14

Difference in delivery mm3/st. 3.5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 7.5 5.5 9.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 7.5 5.5 9.5

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

Boost compensator adjustment

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 7.2 5.2 9.2

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 50 48 52

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 60

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 60

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 375 375 375

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 1250 1250 1250

Overflow quantity cm3/min 420 290 550

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Pressure kPa 431 411 451

Pressure kgf/cm2 4.4 4.2 4.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Pressure kPa 431 411 451

Pressure kgf/cm2 4.4 4.2 4.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 2000 2000 2000

Pressure kPa 647 618 676

Pressure kgf/cm2 6.6 6.3 6.9

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2250 2250 2250

Pressure kPa 716 687 745

Pressure kgf/cm2 7.3 7 7.6

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke mm 3 2.8 3.2

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 670 570 770

Timer stroke mm 0.5 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Timer stroke mm 3 2.8 3.2

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 2000 2000 2000

Timer stroke mm 6.3 5.9 6.7

Oil temperature degC 50 48 52

_05

Pump speed r/min 2250 2250 2250

Timer stroke mm 7.4 7.1 7.8

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 29 28 30

Timer stroke TA mm 2.4 2.4 2.4

Timer stroke variation dT mm 0.6 0.4 0.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 29 28 30

Timer stroke variation dT mm 0.6 0.2 1

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 24 23 25

Timer stroke variation dT mm 1.3 0.9 1.7

Oil temperature degC 50 48 52

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

Control lever angle alpha deg. 20 16 24

Control lever angle beta deg. 33.5 28.5 38.5

Test data Ex:

0000001801 MICROSWITCH ADJUSTMENT

Microswitch adjustment Stepping motor adjustment 1. With the sub-lever and the control lever contacting the idle stopper bolt, adjust the length of the rod so that the stepping motor bracket and the stepping motor lever aligning mark are aligned (Tightening torque T). A = rod B = position of angle alignment marking C = stepping motor bracket D = stepping motor lever 2. Idle position adjustment 1) Fix so that idle stopper contacts the control lever. 2) Insert shim L1 between the sub-lever and the idle stopper. 3) Move the microswitch in the direction of the arrow to turn it ON. 4) Move the microswitch in the direction of the arrow and fix it where it turns OFF using the microswitch fixing bolt. E = microswitch fixing bolt (Tightening torque T2) 3. Full position adjustment 1) 1) Fix so that sub lever contacts the control lever. 2) Insert a shim L2 between the control lever and the full stopper. 3) Turn the plate clockwise as shown in the figure above and confirm that the microswitch turns ON. 4) Move the plate counterclockwise and fix it where the microswitch turns OFF. F = bolt (Tightening torque T2) G = plate
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L1=1.2mm L2=0.7mm T1=3.4~4.9N-m(0.35~0.5kgf-m) T2=2.0~2.9N-m(0.2~0.3kgf-m)
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a=30+-1deg L1=1.2mm L2=0.7mm

0000001901 PARTIAL SETTING

Partial injection quantity adjustment (A) Stopper bolt (B) Fixed nut (C) Sub lever stopper bolt (D) Fixed nut (E) Sub lever 1. At pump speed N1, adjust the stopper bolt (A) so that the idle injection quantity is Q1. Then fix using the nut (B). 2. Confirm that the idle injection quantity is Q2 when the pump speed is N2. 3. Insert a shim L1 between the sub lever (E) and the sub lever stopper bolt (C). Adjust the sub lever stopper bolt so that the injection quantity is Q3 at pump speed N3 and fix using the nut.
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N1=375r/min N2=450r/min N3=1200r/min Q1=7.5+-2.0mm3/st Q2=3--mm3/st Q3=(7.2+-1mm3/st) L1=9.5+-0.1mm
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L1=9.5+-0.1mm