104745-4870 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047454870

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104745-4870 1047454870

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Cross reference number

ZEXEL 104745-4870 1047454870

Zexel num

Bosch num

Firm num

Name

104745-4870

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

(Solenoid timer adjustment condition)
With S/T O-ring; S/T OFF. OFF

Injection timing adjustment

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 46.1 45.6 46.6

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 48.2 45.2 51.2

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 46.1 45.1 47.1

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2150 2150 2150

Average injection quantity mm3/st. 45.1 42.6 47.6

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 15.4 13.4 17.4

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 37 32.5 41.5

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 15.4 12.4 18.4

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10.2 8.2 12.2

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10.2 7.7 12.7

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 45 80

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 50 85

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 350 350 350

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 1100 1100 1100

Overflow quantity with S/T ON cm3/min 460 330 590

Oil temperature degC 50 48 52

_02

Pump speed r/min 1100 1100 1100

Overflow quantity with S/T ON cm3/min 560 430 690

Oil temperature degC 50 48 52

Remarks
Without S/T O-ring; S/T ON.

Stop lever angle

Pump speed r/min 1100 1100 1100

Pressure with S/T ON kPa 569 530 608

Pressure with S/T ON kgf/cm2 5.8 5.4 6.2

Pressure with S/T OFF kPa 490 461 519

Pressure with S/T OFF kgf/cm2 5 4.7 5.3

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1100 1100 1100

Pressure with S/T OFF kPa 490 451 529

Pressure with S/T OFF kgf/cm2 5 4.6 5.4

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1700 1700 1700

Pressure with S/T OFF kPa 637 598 676

Pressure with S/T OFF kgf/cm2 6.5 6.1 6.9

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1100 1100 1100

Timer stroke with S/T ON mm 5.3 4.9 5.7

Timer stroke with S/T OFF mm 3.7 3.5 3.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 700 700 700

Timer stroke with S/T OFF mm 1.3 0.8 1.8

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Timer stroke with S/T ON mm 5.3 4.8 5.8

Timer stroke with S/T OFF mm 3.7 3.4 4

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1700 1700 1700

Timer stroke with S/T OFF mm 6.7 6.2 7.2

Oil temperature degC 50 48 52

_05

Pump speed r/min 2250 2250 2250

Timer stroke with S/T OFF mm 8.6 8.1 9

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 1100 1100 1100

Average injection quantity mm3/st. 30 29.5 30.5

Timer stroke TA mm 2.9 2.7 3.1

Timer stroke variation dT mm 0.8 0.8 0.8

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 30 29 31

Timer stroke TA mm 2.9 2.6 3.2

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_03

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 20 17.5 22.5

Timer stroke TA mm 2.1 1.6 2.6

Oil temperature degC 50 48 52

Remarks
OFF

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.82 5.72 5.92

MS dimension mm 0.9 0.8 1

Control lever angle alpha deg. 25 23 27

Control lever angle beta deg. 36 31 41

Information:

Table 1
Required Parts
Callout Part Number Description Qty
1 7E-3870 Muffler Clamp 1
2 309-3554 Diesel Particulate Filter Group 1
3 309-3592 Clamp Assembly 1
4 309-3864 Tube 1
5 122-4026 Spacer 4
6 7X-0605 Hard Washer 6
7 8T-4244 Nut 2
8 8T-4910 Bolt 4
9 271-6537 Exhaust Monitor Group 1
10 216-7990 Installation Assembly 1
11 282-0031 Remote Display 1
12 220-3778 Adapter Cable Assembly (INTERFACE) 1 Parts Location
Illustration 2 g01549193
(1) 7E-3870 Muffler Clamp (2) 309-3554 Diesel Particulate Filter Group (3) 309-3592 Clamp Assembly (4) 309-3864 Tube (5) 122-4026 Spacer (6) 7X-0605 Hard Washer (7) 8T-4244 Nut (8) 8T-4910 Bolt Installation Procedure
You must read and thoroughly understand the guidelines in Special Instruction, REHS1807, "Installation Guide for Particulate Trap Exhaust Filters" before you attempt any part of the following installation procedure.The installation procedure that follows is specific for the listed machines.Diesel Particulate Filter Installation
Remove the existing muffler.
Illustration 3 g01457287
(A) Flared end (1) 7E-3870 Muffler Clamp (4) 309-3864 Tube
Install 309-3864 Tube (4) by attaching flared end (A) to the turbocharger. Leave 7E-3870 Muffler Clamp (1) loosely attached on the other end of tube (4) .
Illustration 4 g01457295
(3) 309-3592 Clamp Assembly (Lower half) (5) 122-4026 Spacer (6) 7X-0605 Hard Washer (8) 8T-4910 Bolt
Remove the two bolts, two hard washers, two lock washers, and two nuts from 309-3592 Clamp Assembly (3). Keep these parts together with the upper half of the clamp assembly. These parts will be reinstalled in Step 8.
Install the lower half of 309-3592 Clamp Assembly (3) to the existing bracket near the turbocharger by using two 8T-4910 Bolts (8), two 7X-0605 Hard Washers (6), and two 122-4026 Spacers (5). Refer to Illustration 4.
Illustration 5 g01457434
(1) 7E-3870 Muffler Clamp (2) 309-3554 Diesel Particulate Filter Group (4) 309-3864 Tube (5) 122-4026 Spacer (6) 7X-0605 Hard Washer (7) 8T-4244 Nut (8) 8T-4910 Bolt
Install 309-3554 Diesel Particulate Filter Group (2) by inserting the inlet tube of the diesel particulate filter over 309-3864 Tube (4). The weight of the diesel particulate filter group is approximately 40 kg (88 lb).
Secure the diesel particulate filter to the other bracket on the engine block by using two 8T-4910 Bolts (8), two 8T-4244 Nuts (7), two 122-4026 Spacers (5), and four 7X-0605 Hard Washers (6) .
Tighten 7E-3870 Muffler Clamp (1) over the inlet tube of the diesel particulate filter