104742-1391 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047421391

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104742-1391 1047421391

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Cross reference number

ZEXEL 104742-1391 1047421391

Zexel num

Bosch num

Firm num

Name

104742-1391

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

Test data Ex:

0000001801 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Adjust the actuator rod to obtain S1. 2. Apply negative pressure P1 to the actuator and confirm the full stroke. (A) Control lever
----------
S1=1+1mm P1=-53.3kPa(-400mmHg)
----------
S1=1+1mm

Information:

start by:a) remove fuel injection lines**This operation location is in the ENGINE DISASSEMBLY AND ASSEMBLY section. 1. Disconnect the fuel lines from fuel transfer pump (4) and fuel manifold (3). Disconnect fuel line (2) from the fitting. Disconnect the fuel return line to the tank at (1). Install plugs or caps on all fuel line openings.2. Disconnect drain line (5) from the governor housing. Move the fuel lines and drain line clear of the fuel injection pump housing and governor. 3. Remove bolts (6) that hold the oil manifold to the governor housing. 4. Remove cover (7) from the timing gear cover.5. Remove the bolt and washer that hold the timing gear to the camshaft in the fuel injection pump housing. 6. Install tooling (A) and loosen the timing gear on the camshaft in the fuel injection pump housing.7. Fasten a strap and hoist to the fuel injection pump housing and governor as shown. 8. Remove three nuts (8) and remove the fuel injection pump housing and governor. Weight is 25 kg (56 lb.).Install Fuel Injection Pump Housing And Governor
1. Be sure O-ring seals (1) and (2) are in position on the fuel injection pump housing and governor and put clean oil on the O-ring seals.2. Remove the cover on the fuel injection pump housing and install timing pin (A). Turn the camshaft until timing pin (A) goes in the groove in the camshaft as shown. 3. Fasten a strap and hoist to the fuel injection pump housing and governor and put in position on the timing gear plate and oil manifold (3). Install the three nuts that hold the fuel injection pump housing to the timing gear plate and the two bolts that hold the governor housing to oil manifold (3).
After the fuel injection pump housing and governor are installed on the timing gear plate be sure the rack is free to move. The O-ring seal on the drive end of the fuel injection pump can hold the rack and prevent free movement of the rack. If the rack does not move freely remove the fuel injection pump housing and governor and check the O-ring seal on the drive end of the fuel injection pump housing.
4. Install the bolt and washer (4) as shown to hold the timing gear to the camshaft. Install washer (4) with the larger outside diameter toward the bolt head. Tighten the bolt finger tight only.5. Use the following procedure to put the No. 1 piston at top center on the compression stroke. No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures. The engine is seen from the flywheel end when direction of flywheel rotation is given. Do not turn the flywheel backward. a) Remove plug (5) from the flywheel housing and the breather from the valve cover.b) Turn the flywheel counterclockwise until a 3/8"-16 NC bolt (6) at least 2.5 in. long can be installed in the flywheel through the hole in