104745-9350 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047459350

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104745-9350 1047459350

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Cross reference number

ZEXEL 104745-9350 1047459350

Zexel num

Bosch num

Firm num

Name

104745-9350

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 1100 1100 1100

Average injection quantity mm3/st. 49.9 49.4 50.4

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 41.3 38.8 43.8

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 49.9 48.9 50.9

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2150 2150 2150

Average injection quantity mm3/st. 46.3 43.8 48.8

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2550 2550 2550

Average injection quantity mm3/st. 10.9 8.9 12.9

Difference in delivery mm3/st. 3

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 2350 2350 2350

Average injection quantity mm3/st. 39.7 39.7 39.7

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2550 2550 2550

Average injection quantity mm3/st. 10.9 8.4 13.4

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 7.7 5.7 9.7

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. 7.7 5.2 10.2

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. 60 45 80

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 390 260 520

Oil temperature degC 50 48 52

Remarks
With S/T O-ring; S/T ON.

_02

Pump speed r/min 1100 1100 1100

Overflow quantity with S/T ON cm3/min 600 470 730

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 520 481 559

Pressure with S/T ON kgf/cm2 5.3 4.9 5.7

Pressure with S/T OFF kPa 431 402 460

Pressure with S/T OFF kgf/cm2 4.4 4.1 4.7

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_02

Pump speed r/min 1100 1100 1100

Pressure with S/T OFF kPa 431 392 470

Pressure with S/T OFF kgf/cm2 4.4 4 4.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1700 1700 1700

Pressure with S/T OFF kPa 559 520 598

Pressure with S/T OFF kgf/cm2 5.7 5.3 6.1

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1100 1100 1100

Timer stroke with S/T ON mm 3.4 3 3.8

Timer stroke with S/T OFF mm 1.9 1.7 2.1

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 850 850 850

Timer stroke with S/T OFF mm 0.5 0 1

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Timer stroke with S/T ON mm 3.4 2.9 3.9

Timer stroke with S/T OFF mm 1.9 1.6 2.2

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1700 1700 1700

Timer stroke with S/T OFF mm 4.4 3.9 4.9

Oil temperature degC 50 48 52

_05

Pump speed r/min 2300 2300 2300

Timer stroke with S/T OFF mm 6.1 5.6 6.5

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. 31 30.5 31.5

Timer stroke TA mm 1.2 1 1.4

Timer stroke variation dT mm 0.7 0.7 0.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 31 30 32

Timer stroke TA mm 1.2 0.9 1.5

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 22 19.5 24.5

Timer stroke TA mm 0.6 0.1 1.1

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 0.9 0.8 1

Pre-stroke mm 0.1 0.08 0.12

Control lever angle alpha deg. 25 23 27

Control lever angle beta deg. 36 31 41

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

A:Potentiometer standards B:ON, OFF switch standard G:ON-->OFF D:OFF-->ON E:Adjusting point F:Checking point P:Boost pressure Vi:Applied voltage C1:Full-speed C2:Idle Q:Injection quantity N:Pump speed V:Output voltage C:Control lever angle
----------

----------
V1=1.6+-0.03V V2=7.6+-1.1V C3=(4.9+-2.5)deg C4=(19.4+-4)deg Vi=10V P1=-kPa P2=-mmHg

Information:

Connecting Rod
Use the 2H6782 Connecting Rod Boring Machine to recondition connecting rods and to check for connecting rod distortion. The 5P2009 Rework Group is available for the 2H6782 Connecting Rod Boring Machine. To install the rework group see Special Instruction GMG02394.Press a new piston pin bushing into the connecting rod. Assemble new rod bearings and the expansion sleeve. Tighten rod bolt nuts in the following step sequence.1. Put crankcase oil on bolt threads and seating faces of cap and nut.2. Tighten both nuts to 30 3 lb. ft. (40 4 N m).3. Put a mark on each nut and cap.4. Tighten each nut 60° from the mark.Clean spindle and slide the expansion sleeve and connecting rod into place. Install and tighten nut hand tight.Adjust the carrier to the distance between center of the bores, [center-to-center distance is 7.900 .001 in. (200.66 0.03 mm)]. Position the locating rods .25 in. (6.4 mm) from the connecting rod. Install front bushing in bracket and insert locating arbor through front bushing. Slide the centering sleeve over the end of the locating arbor. Slide the locating arbor through the rear bushing, centering sleeve, and into the connecting rod. Tighten knobs until locating rods lightly contact the connecting rod. Lock the locating rods and carrier.To check connecting rod distortion, slide locating arbor in and out of rear bushing. If the locating arbor does not slide freely, recheck horizontal location. If the locating arbor still binds, loosen the carrier clamp and raise or lower the carrier until the locating arbor slides freely. Read the vernier scale and note the variation from the nominal dimension. If the variation exceeds .010 in. (0.25 mm) the rod is distorted and should be replaced. Mark replacement rods for cylinder identification on bearing tab slot side of rod and cap.With the center-to-center distance set to the nominal dimension, set tool in boring bar and insert the boring bar and front bushing. Connect boring bar to the feed mechanism and engage the feed lever. Install the hand crank or an electric drill and flexible adapter and bore the bushing. Use a slow feed rate. Check the bore size. The size is 1.5010 .0003 in. (48.125 0.008 mm). A 5P2050 Connecting Rod Checking Fixture is available for checking connecting rods. For instructions for the use of the checking fixture see Special Instruction SMHS7366.Install connecting rod into piston with boss on rod on same side as crater in piston crown.
CONNECTING ROD AND PISTONWhen installing connecting rod and piston assemblies, inspect the threads of the rod bolts and nuts for damage. The contact surface of the nuts must be flat and free from damage. Damaged parts must be replaced.