104740-0660 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047400660

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-0660 1047400660

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Cross reference number

ZEXEL 104740-0660 1047400660

Zexel num

Bosch num

Firm num

Name

104740-0660

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

Injection timing adjustment

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 53.3 52.8 53.8

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 1000 990 1010

Average injection quantity mm3/st. 53.3 52.3 54.3

Difference in delivery mm3/st. 4.5

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 1900 1890 1910

Average injection quantity mm3/st. 48.1 46 50.2

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 22 19 25

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2200 2200 2200

Average injection quantity mm3/st. 6

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2100 2090 2110

Average injection quantity mm3/st. 22 18.5 25.5

Difference in delivery mm3/st. 6

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 12.7 10.7 14.7

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 12.7 10.2 15.2

Difference in delivery mm3/st. 2.5

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 78 78

Basic *

Oil temperature degC 48 46 50

Timer adjustment_02

Pump speed r/min 100 90 110

Average injection quantity mm3/st. 78 78

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1000 1000 1000

Overflow quantity cm3/min 390 260 520

Stop lever angle

Pump speed r/min 1440 1440 1440

Pressure kPa 569 549 589

Pressure kgf/cm2 5.8 5.6 6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1440 1430 1450

Pressure kPa 569 540 598

Pressure kgf/cm2 5.8 5.5 6.1

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1900 1890 1910

Pressure kPa 755 716 794

Pressure kgf/cm2 7.7 7.3 8.1

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1440 1440 1440

Timer stroke mm 5.7 5.5 5.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 990 1010

Timer stroke mm 2.7 2.7 2.7

Oil temperature degC 50 48 52

_03

Pump speed r/min 1440 1430 1450

Timer stroke mm 5.7 5.3 6.1

Oil temperature degC 50 48 52

_04

Pump speed r/min 1900 1890 1910

Timer stroke mm 8.2 7.5 8.8

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 16 16 16

Test voltage V 25 24 26

0000001401

Pump speed r/min 1440 1440 1440

Average injection quantity mm3/st. 43.8 43.3 44.3

Timer stroke TA mm 5.2 5 5.4

Timer stroke variation dT mm 0.5 0.5 0.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1440 1430 1450

Average injection quantity mm3/st. 43.8 42.8 44.8

Timer stroke TA mm 5.2 4.8 5.6

Oil temperature degC 50 48 52

_03

Pump speed r/min 1440 1430 1450

Average injection quantity mm3/st. 25 23.5 26.5

Timer stroke TA mm 4.7 3.9 5.5

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 1.8 1.7 1.9

Pre-stroke mm 0.2 0.18 0.22

Control lever angle alpha deg. 20 18 22

Control lever angle beta deg. 40 35 45

Information:

Before any service work is done on the fuel system, the outer surface of the injection pump housing must be clean.
1. Disconnect two fuel lines (1) from the fuel transfer pump. 2. Remove two bolts (3) and fuel transfer pump (2).Install Fuel Transfer Pump
1. Put fuel transfer pump (1) in position and install the two bolts that hold it to the fuel pump housing. 2. Connect two lines (2) to the fuel transfer pump.Disassemble Fuel Transfer Pump
start by:a) remove fuel transfer pump 1. Remove bolts (1) that hold transfer pump cover (2) to transfer pump body (5).2. Remove bolts and clamps (4) from the tachometer drive adapter. Remove tachometer drive adapter (3) from the cover. 3. Remove lip type seal (6) from the cover. Remove plug and O-ring seal (7), seat (8), spring (9) and valve (10) from the cover. 4. Remove nut (14) on end of shaft (11) and remove gear (17) and key (12) from the shaft. Remove O-ring seal (13) and the shaft from the body (5).5. Remove idler gear (15) from shaft (16).6. Remove the bearings and the two lip type seals from the body.7. Remove the check valve and shaft (16) from the body.Assemble Fuel Transfer Pump
1. Clean the openings (ports) for the fuel passage in body (3).2. Install shaft (1) and check valve (2) in the body with tooling (A).3. Install smaller bearing (4) in the body with tooling (B). Install the bearing until it is even with the machined surface of the body. 4. Install seal (5) in the body with tooling (C). Install the seal until it is .969 in. (24.6 mm) from the top surface of the body and with the lip toward bearing (4) as shown.5. Install seal (6) in body (3) with tooling (D). Install the seal until it is .563 in. (14.3 mm) from the top surface of the body and with the lip toward the top surface of body (3) as shown. 6. Install the large bearing in body (3) with tooling (E). Install the bearing even with the outside surface of the body. 7. Install the seal in cover (7) with tooling (C). Install the seal with the lip toward the inside of the cover and until it is .750 in. (19.1 mm) below the outside surface of the cover.8. Install the fuel bypass valve, the valve, spring, seal, O-ring seal and plug (14) in the cover. Tighten the plug to a torque of 27 3 lb.ft. (38 4 N m).9. Install shaft (9) in the body. Install gear (13) on the shaft to make an alignment with the gear on the shaft.10. Put 7M7260 Liquid Gasket Material on surface of cover (8). Install the cover on the body.
Do not let liquid gasket material enter the pump.
11. Install the six bolts that hold the cover (7) to the body. Install the O-ring seal to the body. The shaft must turn freely after the bolts that hold the cover in position are tightened.12.