104749-6911 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047496911 8944608051

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104749-6911 1047496911

ISUZU 8944608051 8944608051

Cross reference number

ZEXEL 104749-6911 1047496911

ISUZU 8944608051 8944608051

Zexel num

Bosch num

Firm num

Name

104749-6911
104749-6915

8944608051 ISUZU

INJECTION-PUMP ASSEMBLY
4EC1TC *

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 1500 1500 1500

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 41.9 41.4 42.4

Difference in delivery mm3/st. 3.5

Basic *

Remarks
Full

Injection timing adjustment_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 33.3 32 34.6

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 37.6 37.1 38.1

Difference in delivery mm3/st. 3.5

Basic *

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 31.6 29.1 34.1

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Boost pressure kPa 33.3 32 34.6

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 37.6 36.6 38.6

Difference in delivery mm3/st. 3.5

Basic *

Remarks
CBS

Injection timing adjustment_05

Pump speed r/min 1300 1300 1300

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 42.7 40.7 44.7

Injection timing adjustment_06

Pump speed r/min 1500 1500 1500

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 41.9 40.9 42.9

Difference in delivery mm3/st. 3.5

Basic *

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 1500 1500 1500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 31.4 28.9 33.9

Injection timing adjustment_08

Pump speed r/min 2000 2000 2000

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 37.2 35.2 39.2

Injection timing adjustment_09

Pump speed r/min 2300 2300 2300

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 35.9 33.9 37.9

Injection timing adjustment_10

Pump speed r/min 2500 2500 2500

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 33.4 33.4 33.4

Difference in delivery mm3/st. 4.5

Injection quantity adjustment

Pump speed r/min 2750 2750 2750

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 16.4 13.4 19.4

Difference in delivery mm3/st. 5.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2600 2600 2600

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 26.5 26.5 26.5

Injection quantity adjustment_03

Pump speed r/min 2750 2750 2750

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 16.4 12.9 19.9

Difference in delivery mm3/st. 5.5

Basic *

Injection quantity adjustment_04

Pump speed r/min 2950 2950 2950

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 6

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 6 10

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 6 10

Difference in delivery mm3/st. 2

Basic *

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. 3

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

Remarks
Full

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 at idling position

0000000901

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 590 460 720

_02

Pump speed r/min 2000 2000 2000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 700 570 830

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Pressure kPa 402 382 422

Pressure kgf/cm2 4.1 3.9 4.3

Basic *

Stop lever angle_02

Pump speed r/min 600 600 600

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Pressure kPa 245 216 274

Pressure kgf/cm2 2.5 2.2 2.8

Stop lever angle_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Pressure kPa 402 373 431

Pressure kgf/cm2 4.1 3.8 4.4

Basic *

Stop lever angle_04

Pump speed r/min 2250 2250 2250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Pressure kPa 637 608 666

Pressure kgf/cm2 6.5 6.2 6.8

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Timer stroke mm 3 2.8 3.2

Basic *

_02

Pump speed r/min 650 650 650

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Timer stroke mm 0 0 0

_03

Pump speed r/min 620 620 620

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Timer stroke mm 0.5 0.1 1.5

_04

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Timer stroke mm 3 2.7 3.3

Basic *

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Timer stroke mm 6 5.4 6.6

_06

Pump speed r/min 2250 2250 2250

Boost pressure kPa 69.3 68 70.6

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 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 35.2 34.7 35.7

Timer stroke variation dT mm 1.1 0.9 1.3

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 35.2 34.2 36.2

Timer stroke variation dT mm 1.1 0.8 1.4

Basic *

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 69.3 68 70.6

Boost pressure mmHg 520 510 530

Average injection quantity mm3/st. 27 25.5 28.5

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. 45 40 50

Test data Ex:

0000001801 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 (W) [(V), (W)]. 2. Adjustment of the position of the intermediate lever. Insert a shim (L3) between the control lever (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), (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 N=500r/min R1=20degC R2=-20degC M1=0.7+-0.2mm M2=1.6+-0.4mm K1=3.6+-1deg K2=6.1+-3deg Z1=1.2+-0.3mm Z2=2+-1mm