104745-3750 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047453750


 

Information injection-pump assembly

ZEXEL 104745-3750 1047453750
104745-3750 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 104745-3750 1047453750


Zexel num
Bosch num
Firm num
Name
104745-3750 
 
   
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   750 750 750
Boost pressure kPa   44 42.7 45.3
Boost pressure mmHg   330 320 340
Average injection quantity mm3/st.   59.9 59.4 60.4
Difference in delivery mm3/st.   5
Basic   *
Oil temperature degC   50 48 52
Remarks
CBS
 
Injection timing adjustment_02
Pump speed r/min   1250 1250 1250
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Average injection quantity mm3/st.   62.2 61.7 62.7
Difference in delivery mm3/st.   5
Basic   *
Oil temperature degC   50 48 52
Remarks
Full
 
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.   48.9 46.4 51.4
Oil temperature degC   50 48 52
Injection timing adjustment_04
Pump speed r/min   750 750 750
Boost pressure kPa   44 42.7 45.3
Boost pressure mmHg   330 320 340
Average injection quantity mm3/st.   59.9 58.9 60.9
Basic   *
Oil temperature degC   50 48 52
Remarks
CBS
 
Injection timing adjustment_05
Pump speed r/min   1000 1000 1000
Boost pressure kPa   64 62.7 65.3
Boost pressure mmHg   480 470 490
Average injection quantity mm3/st.   63.3 63.3 63.3
Oil temperature degC   50 48 52
Injection timing adjustment_06
Pump speed r/min   1250 1250 1250
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Average injection quantity mm3/st.   62.2 61.2 63.2
Difference in delivery mm3/st.   5.5
Basic   *
Oil temperature degC   50 48 52
Remarks
Full
 
Injection timing adjustment_07
Pump speed r/min   1750 1750 1750
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Average injection quantity mm3/st.   59 59 59
Oil temperature degC   50 48 52
Injection timing adjustment_08
Pump speed r/min   2100 2100 2100
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Average injection quantity mm3/st.   55.3 52.8 57.8
Oil temperature degC   52 50 54
Injection quantity adjustment
Pump speed r/min   2650 2650 2650
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Average injection quantity mm3/st.   27.1 24.1 30.1
Difference in delivery mm3/st.   8.5
Basic   *
Oil temperature degC   55 52 58
Injection quantity adjustment_02
Pump speed r/min   3050 3050 3050
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Average injection quantity mm3/st.   5
Oil temperature degC   55 52 58
Injection quantity adjustment_03
Pump speed r/min   2650 2650 2650
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Average injection quantity mm3/st.   27.1 22.1 32.1
Difference in delivery mm3/st.   9
Basic   *
Oil temperature degC   55 52 58
Governor adjustment
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   14.5 13 16
Difference in delivery mm3/st.   2
Basic   *
Oil temperature degC   48 46 50
Governor adjustment_02
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   14.5 12.5 16.5
Difference in delivery mm3/st.   2.5
Basic   *
Oil temperature degC   48 46 50
Governor adjustment_03
Pump speed r/min   750 750 750
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   5
Oil temperature degC   50 48 52
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.   80 70 90
Basic   *
Oil temperature degC   48 46 50
Remarks
IDLE
 
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 70 90
Oil temperature degC   48 46 50
Remarks
IDLE
 
Speed control lever angle
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
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
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Overflow quantity cm3/min   420 290 550
Oil temperature degC   50 48 52
Stop lever angle
Pump speed r/min   1250 1250 1250
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Pressure kPa   471 442 500
Pressure kgf/cm2   4.8 4.5 5.1
Basic   *
Oil temperature degC   50 48 52
0000001101
Pump speed r/min   1250 1250 1250
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Timer stroke mm   3.7 3.5 3.9
Basic   *
Oil temperature degC   50 48 52
_02
Pump speed r/min   500 500 500
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Timer stroke mm   1.2 0.6 1.8
Oil temperature degC   48 46 50
_03
Pump speed r/min   750 750 750
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Timer stroke mm   2 1.4 2.6
Oil temperature degC   50 48 52
_04
Pump speed r/min   1250 1250 1250
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Timer stroke mm   3.7 3.3 4.1
Basic   *
Oil temperature degC   50 48 52
_05
Pump speed r/min   1750 1750 1750
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Timer stroke mm   5.8 5.2 6.4
Oil temperature degC   50 48 52
_06
Pump speed r/min   2100 2100 2100
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Timer stroke mm   7.2 6.6 7.8
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
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Average injection quantity mm3/st.   49 48.5 49.5
Timer stroke TA mm   3.1 3.1 3.1
Timer stroke variation dT mm   0.6 0.4 0.8
Basic   *
Oil temperature degC   50 48 52
_02
Pump speed r/min   1250 1250 1250
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Average injection quantity mm3/st.   49 48 50
Timer stroke variation dT mm   0.6 0.2 1
Basic   *
Oil temperature degC   50 48 52
_03
Pump speed r/min   1250 1250 1250
Boost pressure kPa   73.3 72 74.6
Boost pressure mmHg   550 540 560
Average injection quantity mm3/st.   36 35 37
Timer stroke variation dT mm   1.4 0.8 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 0.9 1.1
Control lever angle alpha deg.   57 53 61
Control lever angle beta deg.   43 38 48

Test data Ex:

0000001801 W-CSD ADJUSTMENT

Test data 104745-3750
Adjustment of the W-CSD 1. Adjustment of the advance angle of the timer (1)Determine the timer advance angle using the following graph. (2)(1) Adjust with the screw (A) so that the timer advance angle determined in the item (1) is obtained. X:Temperature t (deg C) Y:Timer stroke TA (mm) (B): Timer stroke TA (mm):
----------

----------
(C)=TA=-0.0376t+1.38(-20<=t)

0000001901 W-FICD LEVER ADJUSTMENT

Test data 104745-3750
2. Adjustment of the W-FICD (1)Insert a block gauge L1 determined from the graph between the control lever (D) and the idling stopper bolt (C). (2)Insert a shim t between the W-CSD lever (E) and the control lever(F). Adjust the W-CSD lever (E) so that it contacts the control lever (F), then fix using the bolt (B). (Tightening torque T). After completing adjustment, screw (G)'s margin must be at least S. Also, remove the block gauge and shims. Note: The temperature of the wax at adjustment must not exceed a. Y:Control lever L (mm) X:Temperature (deg C) H:Block gauge thickness L diagram I
----------
L1=L+-0.05mm t=3+-0.05mm T=3.4~4.9N-m(0.35~0.5kgf-m) a=30degC S=3mm
----------
t=3mm S=Above3mm I=L=-0.201X+8.65(-20<=X) (t=3+-0.05)

0000002001 ACCELERATOR LINK STROKE

Test data 104745-3750
A/T plate adjustment Rotate the control lever from the idle position (B) to the full-speed position (C). Adjust the accelerator link stroke so that (A) (C) - (A) (B) = L3, and fix. (B): B idle position (C): B' full
----------
L3=32.9+-1mm
----------
L1=20.9mm L2=223mm




Information:

The 1674 Diesel Truck Engine is a 638 cu. in (10,5 ltr.) displacement, 4 stroke cycle, 6 cylinder turbocharged and aftercooled engine. This dual overhead cam engine with a 4 valve per cylinder design is made especially for highway trucks hauling big payloads. Serviceability is featured by spin-on throw away fuel filters, easy valve adjustment, replaceable cylinder liners and valve seats, and piston and rod removal from the top.Individual injection pumps, one for each cylinder, meter and pump fuel under high pressure to an injection valve and a precombustion chamber for each cylinder. An automatic variable timing device advances or retards fuel injection and is regulated by engine speed. The faster the engine turns the earlier the injection must take place before piston top center on the compression stroke.A hydro-mechanical governor controls the fuel injection pump out-put to maintain the engine RPM selected by the operator. A speed limiting device, in the governor, limits engine speed until engine oil pressure builds up.Inlet air, filtered by an air cleaner, is compressed by a turbocharger before entering the engine cylinders. The turbocharger is driven by the engine exhaust.There are four in-head valves (two inlet and two exhaust) for each cylinder. Two overhead camshafts, and forked rocker arm assemblies, are located in a housing on top of the cylinder head. The forked rocker arm assemblies act as a direct mechanical link between the lobes on the camshafts and the valve stems. The timing gears are located at the rear of the engine.Coolant for the engine is used to cool the engine lubricating oil. A full-flow temperature regulator, in the cylinder head at the front of the engine, provides for quick engine warm-up, and allows free circulation of coolant after operating temperature has been reached.Lubrication for the engine is supplied by a gear-type pump. The pump provides full pressure lubrication to the engine internal and external parts.The lubricating oil is both cooled and filtered. By-pass valves in the oil cooler assembly provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high or, if either the oil cooler or the oil filter element should become clogged.The starting system is direct electric and uses a 24 or 12 volt starting motor.Efficiency of emission controls and engine performance depends on adherence to proper operation and maintenance recommendations, and use of recommended fuels and lubrication oils. Major adjustments and repair should be entrusted to your authorized dealer. Follow the recommended maintenance schedule with special emphasis on fuel injection nozzles, air cleaner, fuel-air ratio control and high and low idle adjustment. Fuel-air ratio control and the high and low idle adjustments should be made by an authorized dealer.

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