104749-5381 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047495381

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104749-5381 1047495381

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Cross reference number

ZEXEL 104749-5381 1047495381

Zexel num

Bosch num

Firm num

Name

104749-5381

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 32 30.7 33.3

Boost pressure mmHg 240 230 250

Average injection quantity mm3/st. 46.9 46.4 47.4

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 52.3 51.8 52.8

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 39.6 36.6 42.6

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 32 30.7 33.3

Boost pressure mmHg 240 230 250

Average injection quantity mm3/st. 46.9 45.9 47.9

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1500 1500 1500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 37.4 34.9 39.9

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 52.3 51.3 53.3

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 2250 2250 2250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 50.9 47.9 53.9

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2650 2650 2650

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 24.4 21.4 27.4

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2950 2950 2950

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 4

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2650 2650 2650

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 24.4 21.4 27.4

Difference in delivery mm3/st. 5.5

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. 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 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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 150 150 150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 35 25 45

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 150 150 150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 35 25 45

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 72 70.7 73.3

Boost pressure mmHg 540 530 550

Overflow quantity cm3/min 630 500 760

Oil temperature degC 50 48 52

Remarks
Full

_02

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 380 250 510

Oil temperature degC 48 46 50

Remarks
IDLE

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure kPa 412 392 432

Pressure kgf/cm2 4.2 4 4.4

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure kPa 412 392 432

Pressure kgf/cm2 4.2 4 4.4

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 4.7 4.5 4.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 600 600 600

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 0.5 0.1 1.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 4.7 4.5 4.9

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 6.3 5.9 6.7

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 9 8.7 9.4

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 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 0.9 0.8 1

Control lever angle alpha deg. 20 16 24

Control lever angle beta deg. 45 40 50

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjusting method (applied voltage Vi, dummy bolt method) 1. Hold the dummy bolt against the control lever when N=N1, Q=Q1. Fix using the locknut. 2. When adjusting the potentiometer, position the control lever against the dummy bolt and adjust the potentiometer so that the output voltage is V1. 3. After completing adjustment remove the dummy bolt. Confirm that the potentiometer output voltage is as specified above at the control lever idle position and full position. N:Pump speed V:Output voltage Q:Injection quantity P:Boost pressure A:Adjusting point B:Checking point R:Lever position R1:Idle R2:Full speed (C) Nut 013020-6040 (D) Dummy bolt 146526-3300
----------
N1=1000r/min V1=4.76+-0.03V Q1=28.8+-1.0cm3/1,000st Vi=10V
----------
N1=1000r/min V1=4.76+-0.03V V2=(1.06+-0.45)V V3=(8.38+-0.65)V Q1=28.8+-1.0cm3/1,000st

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD (perform with W-FICD released) 1. Adjust to obtain L1. 2. Confirm that L2 is obtained when negative pressure P1 (kPa) {P2 (mmHg)} is applied to the actuator. Adjust the stroke using the actuator stroke adjusting screw (F). (A): Pin (B): Actuator shaft (C): Control lever (D): Actuator (E): Lock nut (torque T)
----------
L1=1+1mm L2=1.32+-0.1mm P1=-53.3kPa P2=-400mmHg
----------
L1=1+1mm L2=1.32+-0.1mm T=1.2~1.5N-m{0.12~0.15kgf-m}

0000002001 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the timer stroke Adjust screw (A) so that the timer stroke is the value determined from the graph. 2. Adjustment of the position of the intermediate lever. Insert a shim L between the control lever I and the idle setscrew G. Align the intermediate lever (F) with the aligning line and fix screw intermediate lever's adjusting (E) so that it contacts the control lever. 3. Adjustment of the FICD Insert a shim LT between the control lever I and the idle setscrew G. Use adjusting screw (B) to fix the CSD lever (C) in the position where it operates the intermediate lever via the rod (D). (J) Aligning mark (O) = timer stroke adjustment (mm): TA = -0.041t+2.42 (P) Lever position (deg): theta 1 = -0.108t+4.79 (-20 deg C <= t <= 20 deg C) Theta 2 = -0.133t + 5.29 (20 deg C =< t =< 50 deg C) (Q) Lever position (mm): L1 = -0.035t+1.57 (-20 deg C <= t <= 20 deg C) L2 = -0.044t + 1.75 (20 deg C =< t =< 50 deg C) The (Q) indicates the clearance between the control lever and the idle set screw. X:Temperature t (deg C) Y1:Timer stroke TA (mm) Y2:Control lever position at theta L (deg, mm) (R) Cooling water temperature (deg C) (S) Cooling water temperature: increase direction N:Pump speed (r/min) (M) Timer piston stroke (mm) (K) Lever angle (deg) (Z) Lever position (mm)
----------
L=1.2+-0.05mm LT=L+-0.05mm
----------
L=1.2+-0.05mm N1=500r/min R1=20degC R2=-20degC M1=1.9+-0.4mm M2=3.4+-0.6mm K1=3.6+-1deg K2=7.9+-3deg Z1=1.2+-0.3mm Z2=2.6+-1mm

0000002101 DASHPOT ADJUSTMENT

Adjustment of the dash pot 1. Hold the position of the control lever (A) at a (gap L). 2. In the above condition, adjust the position of the dash pot so that the tip end of the dash pot (B) contacts the control lever (A) and fix with the nut (C). TT
----------
L=5.2-0.5mm T=6~9N-m(0.6~0.9Kgf-m) a=15.8-1.5deg
----------
L=5.2-0.5mm

Information:

Cylinder Liner
Use same piston which was removed from cylinder liner being checked.Use the following procedure to check a liner:
Fig. 6-Piston to Liner Clearance1. Put piston in liner with piston "front" and liner "front" aligned. Move piston down until bottom edge of piston skirt is 1.00 in. (25.4 mm) (1, Fig. 6) above bottom of liner.Use a feeler gauge to measure distance (2) between piston skirt and liner 90° to piston pin bore. Record the measured distance (2).Piston to cylinder liner clearance for new parts is: 2. Turn piston 90° in liner. Use a feeler gauge to measure distance between piston skirt and liner 90° to piston pin bore. Record the measured distance.The difference between the distance measured in Step 1 and the distance in Step 2 is the distance the liner is out of round at the bottom of the liner.
Fig. 7-Piston to Liner Clearance3. Pull piston out of liner. Put piston in liner up-side down with piston "front" and liner "front" aligned. Move piston so bottom edge of piston skirt is 1.00 in. (25.4 mm) (1, Fig. 7) below top of liner.Use a feeler gauge to measure distance (2) between piston skirt and liner at 90° to piston pin bore. Record the measured distance (2).4. Turn piston 90° in liner. Use a feeler gauge to measure distance between piston skirt and liner 90° to piston pin bore. Record the measured distance.The difference between the distance measured in Step 3 and the distance measured in Step 4 is the distance the liner is out of round at the top of the liner.If liner is out of round more than 0.002 in. (0.05 mm), at top or bottom, install a new one.5. Find difference between distance measured in Step 1 and distance measured in Step 3. This is the distance the liner is tapered.If liner is tapered more than 0.002 in. (0.05 mm), install a new one.Use a wire brush to carefully remove all rust and scale from the outside of the cylinder liners. Make certain there are no nicks or burrs in the areas where the packings will seat.After removing the rust and scale from the cylinder liners wash thoroughly with solvent and dry them.
Fig. 8-D17004BR Cylinder BrushUse D17004BR Cylinder Brush (Fig. 8) to deglaze each cylinder liner. Match the existing cross hatch pattern when deglazing.Refer to "Basic Engine" in FOS Manual-ENGINES for additional information on deglazing cylinder liners.Immediately after deglazing, clean cylinder liner bore with waterless hand cleaner or soap. Rinse cylinder liner bores with clean water until rinse water is clear. Dry liners with clean towels. Wipe bore with clean engine oil. IMPORTANT: Solvents will not remove honing residue.Recheck liner-to-piston skirt clearance. See Group 0403 for piston repair.Piston Cooling Orifices
Inspect for damage or clogging.
Fig. 9-Piston Cooling OrificeIf a piston cooling orifice (2, Fig. 9) is clogged, use a soft wire (1) to push material out of hole.If an orifice is damaged install a new one.Installation
Fig. 10-Piston Cooling OrificesInstall piston cooling orifices (Fig. 10) and tighten to