104760-2031 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047602031

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104760-2031 1047602031

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Cross reference number

ZEXEL 104760-2031 1047602031

Zexel num

Bosch num

Firm num

Name

104760-2031

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105000-2010

Bosch type code NP-DN12SD12TT

Nozzle holder 105780-2080

Opening pressure MPa 14.7 14.7 15.19

Opening pressure kgf/cm2 150 150 155

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840

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)
ON ON

Injection timing adjustment

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 30.5 30 31

Difference in delivery mm3/st. 2.5

Basic *

Injection timing adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 10 6.5 13.5

Injection timing adjustment_03

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 29.9 26.9 32.9

Injection timing adjustment_04

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 30.5 29.5 31.5

Injection timing adjustment_05

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 25.1 23.1 27.1

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 10 7 13

Basic *

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 5

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8.2 6.7 9.7

Difference in delivery mm3/st. 3

Basic *

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8.2 6.2 10.2

Governor adjustment_03

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 4

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50.3 45.3 55.3

Basic *

Speed control lever angle

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1200 1200 1200

Overflow quantity cm3/min 400 270 530

Stop lever angle

Pump speed r/min 1200 1200 1200

Pressure kPa 431.5 402 461

Pressure kgf/cm2 4.4 4.1 4.7

Basic *

Stop lever angle_02

Pump speed r/min 600 600 600

Pressure with S/T ON kPa 294 255 333

Pressure with S/T ON kgf/cm2 3 2.6 3.4

Stop lever angle_03

Pump speed r/min 1200 1200 1200

Pressure with S/T ON kPa 431.5 392 471

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

Stop lever angle_04

Pump speed r/min 2300 2300 2300

Pressure with S/T ON kPa 696 657 735

Pressure with S/T ON kgf/cm2 7.1 6.7 7.5

0000001101

Pump speed r/min 1200 1200 1200

Timer stroke mm 3.5 3.2 3.8

Basic *

_02

Pump speed r/min 1200 1200 1200

Timer stroke with S/T ON mm 3.5 3.1 3.9

Timer stroke with S/T OFF mm 2.7 2.3 3.1

_03

Pump speed r/min 1800 1800 1800

Timer stroke with S/T ON mm 5.8 5.2 6.4

_04

Pump speed r/min 2300 2300 2300

Timer stroke with S/T ON mm 7.35 6.9 7.8

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 6.64 6.54 6.74

MS dimension mm 1.8 1.7 1.9

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 44 39 49

Control lever angle gamma
From idle deg. 8.8 8.3 9.3

Test data Ex:

0000001801 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Fixing the control lever's starting injection quantity adjusting bolt Adjust the bolt so that the starting injection quantity is within the adjustment values, then fix. 2. Fixing the CSD lever stopper At roller holder advance angle a adjust the lever shaft ball pin so that it contacts the roller holder. At this time, fix the stopper so that the distance from the CSD lever is L1. 3. Fixing the wire CSD lever Fix the wire at the CSD lever position for timer lift determined from the graph. 4. FICD lever screw adjustment After fixing the W-CSD lever, move the control lever from the idle position to position b (see figure). In this position, fix the screw so that the clearance between the control lever and the screw is L as determined from the graph. Caution: After fixing the screw, the distance must be L2 or more when the control lever and the head of the screw contact at position b. If not L2 or more, replace the screw with a shorter one (select part no. 146620-1400 or 146620-2800). A = adjusting bolt B = stop lever C = CSD lever D = stopper E = lock screw F = lock bolt G = wire H = control lever I = screw J = FICD lever Y1 = timer lift TA (tolerance+-0.1) Y2 = distance L (tolerance +-0.2) X = wax temperature t (room temperature)
----------
L1=0.5+2mm L2=0.2mm a=0deg b=4.8deg
----------

0000001901 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer At pump speed N1 and at lever angle a from the idle position (shim thickness L), determine the voltage value from the graph using the injection quantity obtained. Then adjust the potentiometer (Applied voltage Vi). Use block 157829-8700 (5.8mm). Y:Voltage X:Injection quantity
----------
N1=700r/min a=8.8deg L=5.8mm Vi=10V
----------

Information:

ACTION REQUIRED
Take the following actions before or after a failure occurs on one or more injectors in any of the engines listed in this service letter.
- If one or more injectors fail it may be necessary to replace up to 6 injectors at the time of repair.
There will be situations when all 6 injectors do not have to be replaced. Refer to next paragraph to determine which injectors should be replaced.
- If an injector repair has previously been performed after approximately 01Oct07 on any of the listed engines, only the injectors that were not replaced at that time should be replaced. This should further be verified by comparing the injector serial numbers in the engine to a range of 3B115776403B to 3B11676551F9. Disregard the first and last two characters in the serial number (in this case "3B" and "3B" in the first serial number and "3B" and "F9" in the second serial number). The reason for verifying the serial number range is due to a batch change of the internal part that is failing. The change was made after serial number 3B11676551F9.
Only injectors falling within the range of 11577640-11676551 should be replaced.
- If the suspect injector can not be identified by using the automatic cylinder cutout test use the two methods below.
- First, run a manual cylinder cutout test at a high engine speed with some load on the engine. When the injector that has failed is cutout, the sound of the engine should be more normal as opposed to the loud knocking heard when the failed injector is active. The second method is to unplug the wiring harness at the valve cover base that sends current to the injector solenoids as well as the harness connection for the injection actuation pressure sensor. By making these disconnections, the fuel injectors will not fire and the HEUI pump will go to maximum actuation pressure. Then remove the valve cover and crank the engine. The injectors that have failed should expel more oil (from the HEUI System) than those that are not failed.
-Refer to RENR9579 for removal/install procedure of the unit injector.
-The serial number of all injectors replaced in an engine covered under this service letter must be documented in the claims story.
SERVICE CLAIM ALLOWANCES
Product smu/age