104742-1371 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047421371

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104742-1371 1047421371

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Cross reference number

ZEXEL 104742-1371 1047421371

Zexel num

Bosch num

Firm num

Name

104742-1371

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

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 -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 46.5 46 47

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 32.3 28.3 36.3

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 600 600 600

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 33 30.5 35.5

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 46.5 45.5 47.5

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1000 1000 1000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 33.5 30.5 36.5

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1400 1400 1400

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 55.2 52.2 58.2

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1800 1800 1800

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 60.2 55.7 64.7

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 17.4 14.4 20.4

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 5

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2100 2100 2100

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 17.4 14.4 20.4

Difference in delivery mm3/st. 4

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 385 385 385

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 8.9 6.9 10.9

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 385 385 385

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 8.9 6.9 10.9

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

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. 60 60 100

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 80 60 100

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 385 385 385

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

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 900 900 900

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Overflow quantity with S/T ON cm3/min 530 330 730

Overflow quantity with S/T OFF cm3/min 480 280 680

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1600 1600 1600

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Pressure with S/T OFF kPa 471 442 500

Pressure with S/T OFF kgf/cm2 4.8 4.5 5.1

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1600 1600 1600

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Pressure with S/T OFF kPa 471 442 500

Pressure with S/T OFF kgf/cm2 4.8 4.5 5.1

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1600 1600 1600

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T OFF mm 3.4 3.1 3.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T ON mm 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1440 1440 1440

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T OFF mm 0.5

Oil temperature degC 50 48 52

_04

Pump speed r/min 1600 1600 1600

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T OFF mm 3.4 3 3.8

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 1800 1800 1800

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T OFF mm 7.4 6.7 7.8

Oil temperature degC 50 48 52

_06

Pump speed r/min 1850 1850 1850

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T OFF mm 7.4 7.1 7.8

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 3.1 3 3.2

KF dimension mm 5.5 5.4 5.6

MS dimension mm 0.4 0.3 0.5

Decrease stroke mm 2.2 2 2.4

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 31 26 36

Information:

Crankshaft Grinding Specifications
The dimensions and finish for grinding crankshafts are as follows:Diameter (A) for connecting rod bearing journals is;.010 in. (0.25 mm) Undersize ... 2.7396 .0006 in.(69.586 0.015 mm).020 in. (0.51 mm) Undersize ... 2.7296 .0006 in.(69.332 0.015 mm).050 in. (1.27 mm) Undersize ... 2.6996 .0006 in.(68.570 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (B) must be .100 .010 in. (2.54 0.25 mm).Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.
DIMENSIONS FOR GRINDING
A. Diameter of connecting rod bearing journals. B. Radius on connecting rod bearing journals. C. Width to grind journals for the connecting rods. D. Diameter of main bearing journals. E. Radius on main bearing journals. F. Width to grind journals for the main bearings.Width (C) is 2.314 .003 in. (58.77 0.08 mm)Diameter (D) for main bearing journals is:.010 in. (0.25 mm) Undersize ... 3.4895 .0006 in.(88.633 0.015 mm).020 in. (0.51 mm) Undersize ... 3.4795 .0006 in.(88.379 0.015 mm).050 in. (1.27 mm) Undersize ... 3.4495 .0006 in.(87.617 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (E) must be .095 .010 in. (2.41 0.25 mm)Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.Width (F) is 1.258 .002 in. (31.95 0.05 mm) for number 4 main bearing journal. Surface finish on the thrust faces of the number 4 main must be 18 micro inches (0.45 micrometers) or less.Width (F) is 1.268 + .020 - .010 in. (32.21 + 0.51 - 0.25 mm) for number 2, 3, and 5 main bearing journals.There is no width (F) for number 1 main bearing journal.When grinding a crankshaft, no material can be removed from the crankshaft webs or counterweights.Crankshaft Gear Removal
Remove the gear using an 8B7548 Push Puller, 8B7551 Bearing Pulling Attachment, 8B75621 Step Plate, and 8H684 Ratchet Box Wrench.
PULLING CRANKSHAFT GEARThe 1P820 Hydraulic Puller Group can also be used to pull gear from crankshaft. Tools required are 1P820 Hydraulic Puller Group, 8B7551 Bearing Pulling Attachment, 8B7549 Puller legs (two), 8B7561 Step Plate, 3H465 Plate (four), 1B4207 Nut (two), and 5P3100 Pump Group.
USING HYDRAULIC PULLERCrankshaft Gear Installation
1. Install the key in keyway of crankshaft. Remove all burrs from key and keyway inside of crankshaft gear.2. Heat gear to 500°F (260°C) maximum.3. Install gear on crankshaft with timing mark on gear facing front of crankshaft.Crankshaft Front Oil Seal Removal
Remove the crankshaft front pulley. Use the 1P3075 Puller Group to remove the crankshaft front oil seal.
REMOVING FRONT OIL SEAL (Typical Example)Remove Crankshaft Rear Seal And Wear Sleeve
Remove the crankshaft rear oil seal with the 1P3075 Puller Group.
REMOVING REAR OIL SEALInstall a 5P7338 Distorter Ring from the 5P7318 Wear Sleeve Distorter Group, in the rear seal bore.
REMOVING REAR WEAR SLEEVE (Typical Example)Install 5P7312 Distorter between distorter ring and wear sleeve. Turn the distorter until the