104749-6340 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047496340 8944134500

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104749-6340 1047496340

ISUZU 8944134500 8944134500

Cross reference number

ZEXEL 104749-6340 1047496340

ISUZU 8944134500 8944134500

Zexel num

Bosch num

Firm num

Name

104749-6340
104749-6342

8944134500 ISUZU

INJECTION-PUMP ASSEMBLY
4EC1T *

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 1000 1000 1000

Boost pressure kPa 42.65 41.3 44

Boost pressure mmHg 320 310 330

Average injection quantity mm3/st. 39.6 39.1 40.1

Difference in delivery mm3/st. 3.5

Basic *

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 44.7 44.2 45.2

Difference in delivery mm3/st. 3.5

Basic *

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 2800 2800 2800

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 18.1 16.6 19.6

Injection timing adjustment_04

Pump speed r/min 2500 2500 2500

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 35.2 33.1 37.3

Injection timing adjustment_05

Pump speed r/min 2250 2250 2250

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 37.2 35.2 39.2

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 44.7 43.7 45.7

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 33.9 31.4 36.4

Injection timing adjustment_08

Pump speed r/min 1000 1000 1000

Boost pressure kPa 42.65 41.3 44

Boost pressure mmHg 320 310 330

Average injection quantity mm3/st. 39.6 38.6 40.6

Remarks
CBS

Injection timing adjustment_09

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 33.9 31.4 36.4

Injection timing adjustment_10

Pump speed r/min 2750 2600 2900

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 18.1 17.1 19.1

Basic *

Remarks
Measure with the angle beta (39~41degC) adjusted to within the specifications.

Injection timing adjustment_11

Pump speed r/min 2500 2500 2500

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 30.65 23.1 38.2

Remarks
Measure with the angle beta (39~41degC) adjusted to within the specifications.

Injection timing adjustment_12

Pump speed r/min 2250 2250 2250

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 36.45 34.2 38.7

Remarks
Measure with the angle beta (39~41degC) adjusted to within the specifications.

Injection quantity adjustment

Pump speed r/min 2800 2800 2800

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 18.1 17.1 19.1

Difference in delivery mm3/st. 5.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2900 2900 2900

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 1 0 2

Remarks
Measure with the angle beta (39~41degC) adjusted to within the specifications.

Governor adjustment

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 8 7 9

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. 8 7 9

Governor adjustment_03

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 2

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 40

Basic *

Speed control lever angle

Pump speed r/min 425 425 425

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 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 459 330 588

Stop lever angle

Pump speed r/min 2000 2000 2000

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Pressure kPa 578.5 559 598

Pressure kgf/cm2 5.9 5.7 6.1

Basic *

Stop lever angle_02

Pump speed r/min 600 600 600

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Pressure kPa 245.5 216 275

Pressure kgf/cm2 2.5 2.2 2.8

Stop lever angle_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Pressure kPa 402 373 431

Pressure kgf/cm2 4.1 3.8 4.4

Stop lever angle_04

Pump speed r/min 2000 2000 2000

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Pressure kPa 578.5 559 598

Pressure kgf/cm2 5.9 5.7 6.1

Stop lever angle_05

Pump speed r/min 2250 2250 2250

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Pressure kPa 637.5 608 667

Pressure kgf/cm2 6.5 6.2 6.8

0000001101

Pump speed r/min 2000 2000 2000

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Timer stroke mm 6 4 8

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Timer stroke mm 3 2.4 3.6

_03

Pump speed r/min 2000 2000 2000

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Timer stroke mm 6 5.7 6.3

_04

Pump speed r/min 2250 2250 2250

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Timer stroke mm 7 6.6 7.4

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 2000 2000 2000

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 30.2 30 30.4

Timer stroke variation dT mm 1.1 1 1.2

Basic *

_02

Pump speed r/min 2000 2000 2000

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 30.2 29.5 30.9

Timer stroke variation dT mm 1.1 0.9 1.3

_03

Pump speed r/min 2000 2000 2000

Boost pressure kPa 69.35 68 70.7

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 25.2 23.7 26.7

Timer stroke variation dT mm 1.5 1 2

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

BCS stroke mm 4 3.9 4.1

Control lever angle alpha deg. 20 16 24

Control lever angle beta deg. 40 37 43

Test data Ex:

0000001801 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the timer stroke Adjust using screw (A) so that the timer stroke is the value determined using the graph (W). [(K), (M)] 2. Adjustment of the position of the intermediate lever. With a shim L5 inserted between the control lever (I) and the FICD set screw (E), insert a shim (L3) between (I) and the idle screw (G). Align the intermediate lever (F) with the aligning mark (J) and then fix the intermediate lever adjusting screw (E) so that (E) contacts the shim between (E) and (I). [(U), (V)] 3. Adjustment of the FICD Insert the shim (L4) between the control lever (I) and the idle set screw (G). Use adjusting screw (B) to fix the CSD lever (C) in the position where it operates the intermediate lever (F) via the rod (D). [(U), (V)] However, set with a shim L5 inserted. [(U), (V), (W)] (O) Timer stroke adjustment (mm) (P): lever angle (deg) (Q): lever angle (deg) 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 (M): timer piston stroke (mm) (K): colored ring (Z): lever position (mm)
----------
L3=1.2+-0.05mm L4=L3+-0.05mm
----------
L3=1.2+-0.05mm L4=L+-0.05mm L5=-mm R1=- R2=- M1=- M2=- K1=- K2=- Z1=- Z2=-