Information injection-pump assembly
ZEXEL
104769-2112
1047692112
Rating:
Cross reference number
ZEXEL
104769-2112
1047692112
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.
31.3
30.9
31.7
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
31.5
29.5
33.5
Oil temperature
degC
50
48
52
Injection timing adjustment_03
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
31.3
30.3
32.3
Difference in delivery
mm3/st.
2.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
30.7
28.7
32.7
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
2300
2300
2300
Average injection quantity
mm3/st.
28.6
26.6
30.6
Oil temperature
degC
52
50
54
Injection timing adjustment_06
Pump speed
r/min
2500
2500
2500
Average injection quantity
mm3/st.
26.3
24.3
28.3
Oil temperature
degC
55
52
58
Injection quantity adjustment
Pump speed
r/min
2600
2600
2600
Average injection quantity
mm3/st.
19
17
21
Difference in delivery
mm3/st.
4.5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_02
Pump speed
r/min
2600
2600
2600
Average injection quantity
mm3/st.
19
15.5
22.5
Difference in delivery
mm3/st.
5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2800
2800
2800
Average injection quantity
mm3/st.
6.5
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
7
6
8
Difference in delivery
mm3/st.
1.1
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
7
5
9
Oil temperature
degC
48
46
50
Boost compensator adjustment
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
8
3
13
Oil temperature
degC
50
48
52
Remarks
From idle
From idle
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
42
38
46
Difference in delivery
mm3/st.
15
Basic
*
Oil temperature
degC
48
46
50
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
Magnet OFF at idling position
Speed control lever angle_02
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
50
48
52
Remarks
Magnet OFF at full-load position
Magnet OFF at full-load position
0000000901
Pump speed
r/min
900
900
900
Overflow quantity
cm3/min
390
260
520
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
900
900
900
Pressure
kPa
373
344
402
Pressure
kgf/cm2
3.8
3.5
4.1
Basic
*
Oil temperature
degC
50
48
52
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
Basic
*
Oil temperature
degC
50
48
52
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
Oil temperature
degC
50
48
52
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
Oil temperature
degC
55
52
58
0000001101
Pump speed
r/min
900
900
900
Timer stroke
mm
1.3
1.1
1.5
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
900
900
900
Timer stroke
mm
1.3
1
1.6
Basic
*
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1200
1200
1200
Timer stroke
mm
3.1
2.7
3.5
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
2300
2300
2300
Timer stroke
mm
8.55
8.1
9
Oil temperature
degC
52
50
54
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
1.8
1.7
1.9
Control lever angle alpha
deg.
25
21
29
Control lever angle beta
deg.
44
39
49
Test data Ex:
0000001801 STARTING I/Q ADJUSTMENT
Starting injection quantity adjustment
Adjust the adjusting bolt (A) so that the starting injection quantity is within the standard and fix using the locknut (B).
(C) Stop lever
----------
----------
----------
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0000001901 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
0000002001 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
Information:
Start By:a. remove oil pump1. Check the connecting rods and caps for their identification and location. 2. Turn the crankshaft until the connecting rod caps are in position.3. Remove two bolts (1) and the cap from the connecting rod. Remove the lower half of the bearing from the cap.4. Push the connecting rod away from the crankshaft. Remove the upper half of the bearing from the connecting rod. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.5. Install the upper half of the bearing in the connecting rod.6. Pull the connecting rod slowly on to the crankshaft.7. Install the lower half of the bearing in the cap. Be sure the tabs in the back of bearings are in the tab grooves of the connecting rod and cap.The serviceman must be very careful to use Plastigage, Tool (A) correctly. The following points must be remembered:Make sure that the backs of the bearings and the bores are clean and dry.Make sure that the bearing locking tabs are properly seated in their slots.The crankshaft must be free of oil where the Plastigage touches it.Put a piece of Plastigage (A) on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing.Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.Do not turn the crankshaft with the Plastigage installed.Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements.Remove the Plastigage before reinstalling the cap.When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004 in) the readings may be low by 0.013 to 0.025 mm (.0005 to .0010 in). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider that the other.For complete details concerning measuring bearing clearance, see the topic, "Engine Bearings & Crankshafts", SEBD0531. 8. Use Plastigage (A) to check the bearing clearance.9. Put Plastigage (A) on the bearing.10. Put 2P2506 Thread Lubricant on the threads of the rod bolts and seat surfaces of the nuts. Be sure the cylinder numbers on the rod cap and rod are the same and are on the same side of connecting rod. Numbers are on the same side of the rod and cap as are the bearing tab slots. If new rods are installed, put the cylinder number on the rod and cap. Do not turn the crankshaft when Plastigage (A) is in position.