104749-6540 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047496540 8944336060

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104749-6540 1047496540

ISUZU 8944336060 8944336060

Cross reference number

ZEXEL 104749-6540 1047496540

ISUZU 8944336060 8944336060

Zexel num

Bosch num

Firm num

Name

104749-6540

8944336060 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. 40 39.5 40.5

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 41.7 36.7 46.7

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 38.6 33.6 43.6

Oil temperature degC 48 46 50

Injection timing adjustment_04

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 39 37.5 40.5

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 40 39 41

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 2250 2250 2250

Average injection quantity mm3/st. 35 33.5 36.5

Oil temperature degC 52 50 54

Injection timing adjustment_07

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 34.9 33.3 36.5

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. 12 11 13

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2650 2650 2650

Average injection quantity mm3/st. 12 11 13

Difference in delivery mm3/st. 4

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8.8 6.8 10.8

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8.8 6.8 10.8

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

Boost compensator adjustment

Pump speed r/min 925 925 925

Average injection quantity mm3/st. 9.5 8.5 10.5

Oil temperature degC 50 48 52

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 75 60 90

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 75 60 90

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 400 400 400

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 2050 2050 2050

Pressure kPa 637 608 666

Pressure kgf/cm2 6.5 6.2 6.8

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke mm 3.9 3.7 4.1

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 630 530 730

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 3.9 3.7 4.1

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1750 1750 1750

Timer stroke mm 6.6 6.2 7

Oil temperature degC 50 48 52

_05

Pump speed r/min 2050 2050 2050

Timer stroke mm 8.2 7.9 8.6

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. 33 32.5 33.5

Timer stroke TA mm 3 3 3

Timer stroke variation dT mm 0.9 0.7 1.1

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 33 32 34

Timer stroke variation dT mm 0.9 0.5 1.3

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 25 24 26

Timer stroke variation dT mm 1.6 1.2 2

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. 37.5 33.5 41.5

Test data Ex:

0000001801 MOTOR LEVER ADJUSTMENT

Motor lever adjustment With the control lever contacting the idle stopper bolt, adjust the length of the rod so that the stepping motor bracket and the motor lever position alignment stamping are aligned. Nut tightening torque: T1 C:Motor lever D:Rod E:Angle aligning stamping position F:Stepping motor bracket (shape may differ)
----------
T1=3.4~4.9N-m(0.35~0.5kgf-m)
----------
a=(30+-1deg)

0000001901 CAM LEVER ADJUSTMENT

Cam lever adjustment 1. First, loosen the cam stopper bolt (A). 2. Insert a shim (B) between the cam lever and the cam stopper bolt and tighten (A) with shim L inserted. Fix (A) in the position where the idle stopper side shim is loosened. Nut tightening torque: T2 L1 is lever idle stopper gap measured at partial characteristics. (A) Cam stopper bolt (B) Shim (H) Cam lever
----------
T2=6~9N-m(0.6~0.9kgf-m)
----------

0000002001 IDLE POSITION ADJUSTMENT

Idle position adjustment 1. Insert a shim L1 between the cam lever and the stopper screw. 2. Move the microswitch in the direction of the arrow so that it turns ON. 3. Turn the microswitch in the direction of the arrow and fix it using the bolts when it turns OFF. (J) Microswitch fixing bolt
----------
L1=2.5mm
----------
T3=2.0~2.9N-m(0.2~0.3kgf-m)

0000002101 FULL POSITION ADJUSTMENT

Full position adjustment (Turn the tension spring pin above the cam lever (in the direction of the arrow) and perform the adjustments below.) 1. Insert a shim L2 between the control lever and the full stopper bolt. 2. Turn the plate clockwise and turn the microswitch ON. 3. Turn the plate counter clockwise and fix it when the microswitch turns OFF. (K) Bolts (2 locations) (O) Plate
----------
L2=0.7mm
----------
L2=0.7mm T3=2.0~2.9N-m(0.2~0.3kgf-m)