Information injection-pump assembly
ZEXEL
104769-2111
1047692111
Rating:
Cross reference number
ZEXEL
104769-2111
1047692111
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
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
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
Right R
Injection timing adjustment
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
31.4
30.9
31.9
Difference in delivery
mm3/st.
2.5
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2600
2600
2600
Average injection quantity
mm3/st.
18.5
15
22
Injection timing adjustment_03
Pump speed
r/min
2300
2300
2300
Average injection quantity
mm3/st.
29.1
27.1
31.1
Injection timing adjustment_04
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
31.4
30.4
32.4
Injection timing adjustment_05
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
31.1
29.1
33.1
Injection quantity adjustment
Pump speed
r/min
2600
2600
2600
Average injection quantity
mm3/st.
18.5
15.5
21.5
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.
7.3
5.8
8.8
Basic
*
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
7.3
5.3
9.3
Difference in delivery
mm3/st.
1.4
Governor adjustment_03
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
4
Boost compensator adjustment
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
7.5
2.5
12.5
Remarks
From idle
From idle
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
44.8
40.8
48.8
Basic
*
Remarks
Refer to additional devices.
Refer to additional devices.
Speed control lever angle
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF
Magnet OFF
0000000901
Pump speed
r/min
900
900
900
Overflow quantity
cm3/min
390
258
522
Stop lever angle
Pump speed
r/min
900
900
900
Pressure
kPa
372.5
343
402
Pressure
kgf/cm2
3.8
3.5
4.1
Basic
*
Stop lever angle_02
Pump speed
r/min
900
900
900
Pressure
kPa
372.5
333
412
Pressure
kgf/cm2
3.8
3.4
4.2
Stop lever angle_03
Pump speed
r/min
1800
1800
1800
Pressure
kPa
588.5
549
628
Pressure
kgf/cm2
6
5.6
6.4
Stop lever angle_04
Pump speed
r/min
2500
2500
2500
Pressure
kPa
735.5
696
775
Pressure
kgf/cm2
7.5
7.1
7.9
0000001101
Pump speed
r/min
900
900
900
Timer stroke
mm
1.3
1.1
1.5
Basic
*
_02
Pump speed
r/min
900
900
900
Timer stroke
mm
1.3
1
1.6
_03
Pump speed
r/min
1200
1200
1200
Timer stroke
mm
3.1
2.7
3.5
_04
Pump speed
r/min
2300
2300
2300
Timer stroke
mm
8.55
8.1
9
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. 11 10.5 11.5
From idle deg. 11 10.5 11.5
Test data Ex:
0000001801 W-CSD ADJUSTMENT
Adjustment of the W-CSD
Adjust the timer stroke determined from the graph below using the screw.
Caution: The temperature of the wax at adjustment must not exceed a.
A = screw
Y = timer stroke TA
X = temperature t
----------
a=30degC
----------
t-TA;-10<=t(degC)<=20 TA=-0.0367t+1.284 20<=t(degC)<=40 TA=-0.0275t+1.1
----------
a=30degC
----------
t-TA;-10<=t(degC)<=20 TA=-0.0367t+1.284 20<=t(degC)<=40 TA=-0.0275t+1.1
0000001901 DASHPOT ADJUSTMENT
Adjustment of the dash pot
1. Insert a block gauge L1 (thickness gauge) between the idle set screw and the bracket.
2. In the above condition, adjust the elongated hole so that the pushrod contacts the control lever. Then, fix using the bolt.
TT
Note:
(1)The dashpot and control lever contact faces must be smooth.
(2)Confirm that the control lever returns to the idling position.
ISC actuator installation
1. Maintain the control lever in the idling position.
2. Fix the actuator bracket (A) so that the clearance between the control lever and the ISC lever's roller (B) is L2.
----------
L1=3.8+-0.05mm L2=1.5+-0.5mm T=6~9N-m{0.6~0.9kgf-m}
----------
L1=3.8+-0.05mm L2=1.5+-0.5mm
----------
L1=3.8+-0.05mm L2=1.5+-0.5mm T=6~9N-m{0.6~0.9kgf-m}
----------
L1=3.8+-0.05mm L2=1.5+-0.5mm
0000002001 STARTING I/Q ADJUSTMENT
Starting injection quantity adjustment
Fix the stop lever's starting injection quantity adjusting bolt. At adjustment, adjust the bolt so that the starting injection quantity is as specified and then fix using the locknut.
A = stop lever
B = locknut
C = adjusting bolt
----------
----------
a=32+-4deg
----------
----------
a=32+-4deg
Information:
Start By:a. remove timing gear coverb. remove fuel injection pump housing and governor 1. Remove four bolts (2), plate (3) and idler gear (1). 2. If the camshaft is not going to be removed, use Tool (A) to remove camshaft gear (4).
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves or both.
3. Remove bolts (5) that hold timing gear plate (6) to the cylinder block.4. Remove timing gear plate (6). 5. Use Tool (B) to remove the bearing from the idler gear. The following steps are for the installation of the timing gears and plate.6. Install a new gasket on the timing gear plate.7. Put timing gear plate (6) in position on the cylinder block and install the bolts that hold the timing gear plate to the cylinder block.8. Heat camshaft gear (4) to a maximum temperature of 205° C (400° F) for no longer than three hours and install it on the camshaft.9. Use Tool (B) and install the bearing in the idler gear. Set the gear on the front face (face with the timing marks). Drive the bearing from the rear face toward the front face of the gear. Install the bearing to a depth of 1.5 0.5 mm (.06 .02 in) below the rear face of the idler gear.10. Install the idler gear, plate and bolts. Be sure No. 1 cylinder is at top center on the compression stroke. Install the idler gear so "V" mark (7) on the idler gear is in alignment with the "V" mark on the crankshaft gear. "K" marks (8) on the camshaft gear can be seen at the outer edges of the idler gear.End By:a. install fuel injection pump housing and governorb. install timing gear cover
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves or both.
3. Remove bolts (5) that hold timing gear plate (6) to the cylinder block.4. Remove timing gear plate (6). 5. Use Tool (B) to remove the bearing from the idler gear. The following steps are for the installation of the timing gears and plate.6. Install a new gasket on the timing gear plate.7. Put timing gear plate (6) in position on the cylinder block and install the bolts that hold the timing gear plate to the cylinder block.8. Heat camshaft gear (4) to a maximum temperature of 205° C (400° F) for no longer than three hours and install it on the camshaft.9. Use Tool (B) and install the bearing in the idler gear. Set the gear on the front face (face with the timing marks). Drive the bearing from the rear face toward the front face of the gear. Install the bearing to a depth of 1.5 0.5 mm (.06 .02 in) below the rear face of the idler gear.10. Install the idler gear, plate and bolts. Be sure No. 1 cylinder is at top center on the compression stroke. Install the idler gear so "V" mark (7) on the idler gear is in alignment with the "V" mark on the crankshaft gear. "K" marks (8) on the camshaft gear can be seen at the outer edges of the idler gear.End By:a. install fuel injection pump housing and governorb. install timing gear cover