104746-1150 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047461150

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104746-1150 1047461150

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Cross reference number

ZEXEL 104746-1150 1047461150

Zexel num

Bosch num

Firm num

Name

104746-1150

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)
Left L

Injection timing adjustment

Pump speed r/min 600 600 600

Boost pressure kPa 30 28.7 31.3

Boost pressure mmHg 225 215 235

Average injection quantity mm3/st. 63.8 63.3 64.3

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 69.7 69.2 70.2

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 600 600 600

Boost pressure kPa 30 28.7 31.3

Boost pressure mmHg 225 215 235

Average injection quantity mm3/st. 63.8 62.8 64.8

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 55.9 55.9 55.9

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 69.7 68.7 70.7

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 54.3 54.3 54.3

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1800 1800 1800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 67.9 67.9 67.9

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 34.6 31.6 37.6

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2550 2550 2550

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 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 34.6 31.6 37.6

Difference in delivery mm3/st. 5.5

Oil temperature degC 52 50 54

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. 15.8 13.8 17.8

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. 15.8 13.8 17.8

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. 105 105 145

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. 105 105 145

Oil temperature degC 48 46 50

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

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 650 520 780

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 490 470 510

Pressure kgf/cm2 5 4.8 5.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 490 470 510

Pressure kgf/cm2 5 4.8 5.2

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 3.3 3.1 3.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 675 675 675

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 0.5 0.1 1.3

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

Timer stroke mm 3.3 3.1 3.5

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 4.5 4.1 4.9

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 6.6 6.3 7

Oil temperature degC 50 48 52

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. 47.9 46.9 48.9

Timer stroke TA mm 2.4 2.2 2.6

Timer stroke variation dT mm 0.9 0.9 0.9

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. 47.9 46.4 49.4

Timer stroke TA mm 2.4 2 2.8

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. 31.3 29.8 32.8

Timer stroke TA 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 0.7 0.6 0.8

BCS stroke mm 3 2.8 3.2

Control lever angle alpha deg. 24 20 28

Control lever angle beta deg. 45 40 50

Test data Ex:

0000001801 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the advance angle of the timer (1)Determine the timer advance angle from the graph in Fig. 2 (D). (2)(1) Adjust with the screw so that the timer advance angle determined in the item (1) is obtained. (C) Fig. 1 (D) Fig. 2 (A): TA+-0.1 (B): Timer stroke TA: X:Temperature X Y:Timer stroke TA (mm)
----------

----------
(B)=-10<=t(degC)<=20:TA=-0.0367t+1.284 (D)=20<=t(degC)<=40:TA=-0.0275t+1.1

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Mount the V-FICD after the completion of potentiometer adjustment. 2. Confirm that the clearance between the control lever (B) and the actuator rod (A) is at least L1. 3. Insert the L2 shim between the control lever (D) and the idle set screw (C). 4. Adjust the stroke adjusting screw (E) so that the actuator moves through its full stroke, then fix using nut (F). Note When adjustment is not possible using the stroke adjusting screw (E), move the actuator rod position using (G), (H) and (I). Adjust again the stroke with (E) and (F). 5. Apply negative pressure P1 {P2} to the actuator and confirm that it moves through its full stroke. 6. After releasing negative pressure, re-confirm that the clearance between (A) and (B) is at least L1.
----------
L1=1mm L2=2.19+-0.1mm P1=-53.3kPa P2=-400mmHg
----------
L1=Above1mm L2=2.19+-0.1mm T1=3.4~4.9N-m(0.35~0.50kgf-m) T2=1.4~2.0N-m(0.14~0.20kgf-m)

Information:

Bearings
Anti-Friction Bearings
When an anti-friction bearing is removed, cover it to keep out dirt and abrasives. Wash the bearings in nonflammable cleaning solution and allow them to drain dry. The bearings may be dried with compressed air, but DO NOT SPIN THE BEARING. Discard the bearings if the races and balls or rollers are pitted, scored or burned. If the bearing is serviceable, coat it with oil and wrap it in clean paper. DO NOT unwrap new bearings until time of installation.The life of an anti-friction bearing will be shortened if not properly lubricated.Double Row, Tapered Roller
Double row, tapered roller bearings are precision fit during manufacture and the components are not interchangeable. The cups, cones and spacers are usually etched with the same serial number and letter designator. If no letter designators are found, wire the components together to assure correct installation. Reusable bearing components should be installed in their original positions.Heating Bearings
Bearings which require expansion for installation should be heated in oil not to exceed 121°C (250°F). When more than one part is heated to aid in assembly, they must be allowed to cool and then pressed together again. Parts often separate as they cool and shrink.Installation
Lubricate new or used bearings before installation. Bearings that are to be preloaded must have a film of oil over the entire assembly to obtain accurate preloading. When installing a bearing, spacer or washer against a shoulder on a shaft, be sure the chamfered side is toward the shoulder. When pressing bearings into a retainer or bore, apply pressure to the outer race. If the bearing is pressed on the shaft, apply pressure on the inner race.Preload
Preload is an initial force placed on the bearing at the time of assembly.Determine preload or end clearance form the Specifications Section of this Service Manual. Care should be exercised in applying preload. Misapplication of preload to bearings requiring end clearance can result in bearing failure.Sleeve Bearings
DO NOT INSTALL SLEEVE BEARINGS WITH A HAMMER. Use a press, if possible and apply the pressure directly in line with the bore. If it is necessary to drive on a bearing, use a driver or a bar with a smooth flat end. If a sleeve bearing has an oil hole, align it with the oil hole in the mating part.