104749-6541 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047496541

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Information injection-pump assembly

ZEXEL 104749-6541 1047496541

Components :

0.	INJECTION-PUMP ASSEMBLY	104749-6541
1.	_
2.	FUEL INJECTION PUMP
3.	NUMBER PLATE	146646-4300
4.	_	146672-2720
5.	CAPSULE
6.	ADJUSTING DEVICE
7.	NOZZLE AND HOLDER ASSY	105158-2090
8.	Nozzle and Holder	8-94418-161-0
9.	Open Pre:MPa(Kqf/cm2)	13.2{135}
10.	NOZZLE-HOLDER	105088-1042
11.	NOZZLE	105007-1061

Scheme ###:

1/6.	[1]	146601-0100	PACKING RING
6.	[1]	146100-0120	SUPPLY PUMP D20
9.	[1]	146103-0000	COVER
10.	[2]	139104-0000	FLAT-HEAD SCREW
12/1.	[1]	146200-0500	DRIVE SHAFT
12/2.	[1]	146201-0000	WOODRUFF KEY
12/3.	[2]	146202-0001	DAMPER
12/4.	[1]	146203-0000	TOOTHED GEAR
17.	[1]	146204-0000	PLAIN WASHER
20.	[1]	146210-0120	ROLLER SET MMC C=1.2
24.	[1]	146303-0000	BEARING PIN
25.	[1]	146304-0000	BEARING PIN
26.	[1]	146305-0000	CLAMPING BAND
27.	[1]	146205-0000	SLOTTED WASHER
29.	[1]	146220-0020	CAM PLATE '00'SK3277
30.	[1]	146600-0800	O-RING
31.	[1]	146300-0600	PUMP PLUNGER ' 6' 5-10
32.	[1]	146301-0000	SLIDING PIECE
33.	[1]	146603-0700	SHIM
34.	[1]	146302-0100	COMPRESSION SPRING K=2.25
35/1.	[1]	146603-0700	SHIM
35/1.	[1]	146603-0800	SHIM
35/1.	[1]	146603-0900	SHIM
35/1.	[1]	146603-1000	SHIM
35/1.	[1]	146603-1100	SHIM
35/1.	[1]	146603-3600	SHIM
36.	[1]	146600-0800	O-RING
37.	[1]	146310-0000	COVER
38.	[2]	139106-0000	FLAT-HEAD SCREW
39.	[1]	146310-0100	COVER
40.	[2]	139106-0000	FLAT-HEAD SCREW
43.	[1]	146230-0000	SHIM
44.	[1]	146230-0100	PLAIN WASHER
45.	[1]	146231-0000	SLOTTED WASHER
47.	[2]	146233-0000	SLOTTED WASHER
48/1.	[1]	146603-0000	SHIM
48/1.	[1]	146603-0100	SHIM
48/1.	[1]	146603-0200	SHIM
48/1.	[1]	146603-0300	SHIM
48/1.	[1]	146603-0400	SHIM
48/1.	[1]	146603-0500	SHIM
48/1.	[1]	146603-0600	SHIM
48/1.	[1]	146690-1400	SHIM
48/1.	[1]	146690-1500	SHIM
48/1.	[1]	146690-1600	SHIM
48/1.	[1]	146690-1700	SHIM
48/1.	[1]	146690-1800	SHIM
48/1.	[1]	146690-1900	SHIM
49.	[2]	146234-0020	GUIDE PIN
50.	[1]	146400-8420	HYDRAULIC HEAD D9 2X2.2 A0.6
50.	[1]	146400-8420	HYDRAULIC HEAD D9 2X2.2 A0.6
50.	[1]	146400-8420	HYDRAULIC HEAD D9 2X2.2 A0.6
51.	[1]	146600-0000	O-RING
52/1.	[1]	146420-0000	SHIM
52/1.	[1]	146420-0100	SHIM
52/1.	[1]	146420-0200	SHIM
52/1.	[1]	146420-0300	SHIM
52/1.	[1]	146420-0400	SHIM
52/1.	[1]	146420-0500	SHIM
52/1.	[1]	146420-0600	SHIM
52/1.	[1]	146420-0700	SHIM
52/1.	[1]	146420-0800	SHIM
52/1.	[1]	146420-0900	SHIM
52/1.	[1]	146420-1000	SHIM
52/1.	[1]	146420-1100	SHIM
52/1.	[1]	146420-1200	SHIM
52/1.	[1]	146420-1300	SHIM
52/1.	[1]	146420-1400	SHIM
52/1.	[1]	146420-1500	SHIM
52/1.	[1]	146420-1600	SHIM
52/1.	[1]	146420-1700	SHIM
52/1.	[1]	146420-1800	SHIM
52/1.	[1]	146420-1900	SHIM
52/1.	[1]	146420-2000	SHIM
52/1.	[1]	146420-2100	SHIM
52/1.	[1]	146420-2200	SHIM
52/1.	[1]	146420-2300	SHIM
52/1.	[1]	146420-2400	SHIM
52/1.	[1]	146420-2500	SHIM
52/1.	[1]	146420-2600	SHIM
52/1.	[1]	146420-2700	SHIM
52/1.	[1]	146420-2800	SHIM
52/1.	[1]	146420-2900	SHIM
52/1.	[1]	146420-3000	SHIM
52/1.	[1]	146420-3100	SHIM
52/1.	[1]	146420-3200	SHIM
52/1.	[1]	146420-3300	SHIM
52/1.	[1]	146420-3400	SHIM
52/1.	[1]	146420-3500	SHIM
52/1.	[1]	146420-3600	SHIM
52/1.	[1]	146420-3700	SHIM
52/1.	[1]	146420-3800	SHIM
52/1.	[1]	146420-3900	SHIM
52/1.	[1]	146420-4000	SHIM
52/1.	[1]	146420-4100	SHIM
52/1.	[1]	146420-4200	SHIM
52/1.	[1]	146420-4300	SHIM
52/1.	[1]	146420-4400	SHIM
52/1.	[1]	146420-4500	SHIM
52/1.	[1]	146420-4600	SHIM
52/1.	[1]	146420-4700	SHIM
52/1.	[1]	146420-4800	SHIM
52/1.	[1]	146420-4900	SHIM
52/1.	[1]	146420-5000	SHIM
52/1.	[1]	146420-5100	SHIM
52/1.	[1]	146420-5200	SHIM
52/1.	[1]	146420-5300	SHIM
52/1.	[1]	146420-5400	SHIM
52/1.	[1]	146420-5500	SHIM
52/1.	[1]	146420-5600	SHIM
52/1.	[1]	146420-5700	SHIM
52/1.	[1]	146420-5800	SHIM
54.	[4]	146433-0100	GASKET
55.	[4]	146430-0120	DELIVERY-VALVE ASSEMBLY 'VE2' VR25
56.	[4]	146432-0000	COMPRESSION SPRING K=0.48
58.	[4]	146440-0120	FITTING D0.45 L=55
60.	[3]	139106-0100	FLAT-HEAD SCREW
66.	[1]	146600-0100	O-RING
67.	[1]	146503-0220	GOVERNOR COVER
67/13.	[2]	013020-6040	UNION NUT
67/13.	[2]	013020-6040	UNION NUT
67/14.	[1]	029240-6010	UNION NUT
67/15.	[1]	146526-0300	BLEEDER SCREW
67/16.	[1]	146526-0200	BLEEDER SCREW
67/23.	[1]	146628-9420	BRACKET
67/78.	[1]	146600-1000	SEAL RING
68.	[1]	146510-8220	CONTROL SHAFT R=10 S R
69.	[1]	139310-0200	PLAIN WASHER
72.	[1]	146535-3720	CONTROL LEVER '537'
72B.	[1]	146535-3820	CONTROL LEVER '538'
73.	[1]	014110-6440	LOCKING WASHER
75.	[1]	013020-6040	UNION NUT
87.	[1]	139308-0300	PLAIN WASHER
88.	[1]	146545-1620	THREADED PIN
90.	[1]	139208-0100	UNION NUT
91.	[1]	146600-1200	O-RING
95.	[1]	146551-4620	FULCRUM LEVER I=2.2 SKH5
104.	[2]	146568-0000	SLOTTED SPRING PIN
105.	[2]	026508-1140	GASKET
106.	[2]	146588-0000	COILED SPRING
107.	[1]	146569-0100	UNION NUT
108.	[1]	146570-0320	GOVERNOR SHAFT L-L/T
109.	[1]	146600-0400	O-RING
110/1.	[1]	146571-0000	SHIM
110/1.	[1]	146571-0100	SHIM
110/1.	[1]	146571-0200	SHIM
110/1.	[1]	146571-0300	SHIM
110/1.	[1]	146571-0400	SHIM
110/1.	[1]	146571-0500	SHIM
110/1.	[1]	146571-0600	SHIM
110/1.	[1]	146571-0700	SHIM
110/1.	[1]	146571-0800	SHIM
111.	[1]	146602-0600	PLAIN WASHER
112.	[1]	146572-0020	FLYWEIGHT ASSEMBLY
114.	[1]	146602-0500	PLAIN WASHER
115.	[1]	146575-3200	SLIDING SLEEVE '32' D2.0 2-0.
116.	[1]	146576-0000	SEALING CAP
117/1.	[1]	146577-1800	PLUG
117/1.	[1]	146577-1900	PLUG
117/1.	[1]	146577-2000	PLUG
117/1.	[1]	146577-2100	PLUG
117/1.	[1]	146577-2200	PLUG
117/1.	[1]	146577-2300	PLUG
117/1.	[1]	146577-2400	PLUG
117/1.	[1]	146577-2500	PLUG
117/1.	[1]	146577-2600	PLUG
117/1.	[1]	146577-2700	PLUG
117/1.	[1]	146577-2800	PLUG
117/1.	[1]	146577-2900	PLUG
117/1.	[1]	146577-3000	PLUG
117/1.	[1]	146577-3100	PLUG
117/1.	[1]	146577-3200	PLUG
117/1.	[1]	146577-3300	PLUG
117/1.	[1]	146577-6700	PLUG
117/1.	[1]	146577-6800	PLUG
117/1.	[1]	146577-6900	PLUG
117/1.	[1]	146577-7000	PLUG
117/1.	[1]	146577-7100	PLUG
117/1.	[1]	146577-7200	PLUG
117/1.	[1]	146577-7300	PLUG
117/1.	[1]	146577-7400	PLUG
117/1.	[1]	146577-7500	PLUG
117/1.	[1]	146577-7600	PLUG
117/1.	[1]	146577-7700	PLUG
117/1.	[1]	146577-7800	PLUG
117/1.	[1]	146577-7900	PLUG
117/1.	[1]	146577-8000	PLUG
117/1.	[1]	146577-8100	PLUG
123.	[4]	139106-0200	FLAT-HEAD SCREW
130.	[1]	146421-0020	CAPSULE D14
130/2.	[1]	026508-1140	GASKET
130/3.	[1]	146422-0000	BLEEDER SCREW
130/4.	[1]	146600-0500	O-RING
133.	[1]	146600-0600	O-RING
134.	[1]	146600-0700	O-RING
135.	[1]	146110-0920	CONTROL VALVE '09'4XD1.6K=2.
135/5.	[1]	146114-0000	SPRING WASHER
136.	[1]	146120-0120	OVER FLOW VALVE
137.	[2]	026512-1840	GASKET
138.	[1]	146605-3720	INLET UNION OUT B1 B2
200.	[1]	146206-0100	COILED SPRING
205.	[1]	146201-0100	WOODRUFF KEY
218.	[1]	146587-7320	COILED SPRING
220.	[1]	146587-7600	COILED SPRING
225.	[1]	146627-7120	BRACKET
230.	[1]	146628-1800	BRACKET
231.	[1]	139106-0500	FLAT-HEAD SCREW
237.	[1]	146620-0200	HEX-SOCKET-HEAD CAP SCREW
239.	[1]	023500-5140	PLAIN WASHER
240.	[1]	146650-1220	PULLING ELECTROMAGNET
240/8.	[1]	146600-1700	O-RING
242.	[1]	146658-4620	WIRE ' 46' 12V
243.	[1]	013020-5240	UNION NUT
244.	[1]	146613-5620	PLATE
245.	[3]	026512-1840	GASKET
246.	[1]	146125-0020	EYE BOLT
247.	[1]	146606-7020	INLET UNION IN B3
248.	[1]	146614-0200	SPACER BUSHING
275.	[1]	146619-6220	BRACKET
276.	[2]	010010-2040	BLEEDER SCREW
277.	[2]	014111-0440	LOCKING WASHER
450.	[1]	146676-2820	ADJUSTING DEVICE
455.	[1]	146541-7220	RACK
460.	[2]	016010-0440	LOCKING WASHER
465.	[1]	146616-4200	SPACER BUSHING
470.	[1]	139106-0500	FLAT-HEAD SCREW
471.	[1]	139106-0400	FLAT-HEAD SCREW
472.	[2]	010206-1040	HEX-SOCKET-HEAD CAP SCREW
800S.	[1]	146009-4720	PUMP HOUSING
800S/1/6.	[1]	146601-0100	PACKING RING
800S/1/6.	[1]	146601-0100	PACKING RING
804S.	[1]	146232-0220	COMPRESSION SPRING
805S.	[1]	146574-0120	PARTS SET
810S.	[1]	146600-1120	REPAIR SET
903.	[1]	146672-2720	PULSE GENERATOR
903/2.	[1]	146600-1300	O-RING
906.	[1]	146646-4300	NUMBER PLATE

Include in #2:

104749-6541 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 104749-6541 1047496541

Zexel num

Bosch num

Firm num

Name

104749-6541
104749-5060

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. 8 6 10

Basic *

Oil temperature degC 50 48 52

Remarks
From idle

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)