104740-1940 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401940

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1940 1047401940

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Cross reference number

ZEXEL 104740-1940 1047401940

Zexel num

Bosch num

Firm num

Name

104740-1940

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 1300 1300 1300

Average injection quantity mm3/st. 32.5 32 33

Difference in delivery mm3/st. 3

Basic *

Injection timing adjustment_02

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 46.3 40.8 51.8

Injection timing adjustment_03

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 34.3 29.8 38.8

Injection timing adjustment_04

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 30.4 27.9 32.9

Injection timing adjustment_05

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 31.9 30.4 33.4

Injection timing adjustment_06

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 32.5 31.5 33.5

Difference in delivery mm3/st. 3

Basic *

Injection timing adjustment_07

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 34.2 32.2 36.2

Injection timing adjustment_08

Pump speed r/min 2250 2250 2250

Average injection quantity mm3/st. 34.3 32.3 36.3

Injection quantity adjustment

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 11.2 8.2 14.2

Difference in delivery mm3/st. 4

Basic *

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 5

Injection quantity adjustment_03

Pump speed r/min 2400 2400 2400

Average injection quantity mm3/st. 32.3 26.8 37.8

Injection quantity adjustment_04

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 11.2 7.7 14.7

Difference in delivery mm3/st. 4

Basic *

Governor adjustment

Pump speed r/min 435 435 435

Average injection quantity mm3/st. 10.1 8.1 12.1

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 435 435 435

Average injection quantity mm3/st. 10.1 7.6 12.6

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_03

Pump speed r/min 620 620 620

Average injection quantity mm3/st. 6

Timer adjustment

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 44 34 54

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 44 34 54

Remarks
IDLE

Speed control lever angle

Pump speed r/min 435 435 435

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1250 1250 1250

Overflow quantity cm3/min 640 510 770

Stop lever angle

Pump speed r/min 1250 1250 1250

Pressure kPa 431 411 451

Pressure kgf/cm2 4.4 4.2 4.6

Basic *

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Pressure kPa 363 334 392

Pressure kgf/cm2 3.7 3.4 4

Stop lever angle_03

Pump speed r/min 1250 1250 1250

Pressure kPa 431 411 451

Pressure kgf/cm2 4.4 4.2 4.6

Basic *

Stop lever angle_04

Pump speed r/min 1750 1750 1750

Pressure kPa 569 520 618

Pressure kgf/cm2 5.8 5.3 6.3

Stop lever angle_05

Pump speed r/min 2100 2100 2100

Pressure kPa 647 608 686

Pressure kgf/cm2 6.6 6.2 7

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke mm 3.8 3.6 4

Basic *

_02

Pump speed r/min 800 800 800

Timer stroke mm 1.6 0.4 2.8

_03

Pump speed r/min 1000 1000 1000

Timer stroke mm 2.3 1.3 3.3

_04

Pump speed r/min 1250 1250 1250

Timer stroke mm 3.8 3.5 4.1

Basic *

_05

Pump speed r/min 1750 1750 1750

Timer stroke mm 6.8 6.2 7.4

_06

Pump speed r/min 2100 2100 2100

Timer stroke mm 7 6.6 7.4

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 20.3 19.3 21.3

Timer stroke TA mm 3.1 2.9 3.3

Timer stroke variation dT mm 0.7 0.7 0.7

Basic *

_02

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 20.3 18.8 21.8

Timer stroke TA mm 3.1 2.8 3.4

Timer stroke variation dT mm 0.7 0.7 0.7

Basic *

_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 10.8 9.3 12.3

Timer stroke TA mm 2.1 1.6 2.6

Timer stroke variation dT mm 1.3 1.3 1.3

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

Pre-stroke mm 0.19 0.17 0.21

Control lever angle alpha deg. 20 16 24

Control lever angle beta deg. 45 40 50

Test data Ex:

0000001801 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the timer stroke Adjust using screw (A) so that the timer stroke is the value determined using the graph (M). [(K), (M)] 2. Adjustment of the position of the intermediate lever. Insert the shim (L1) between the control lever (I) and the idle set screw (G). Align the intermediate lever (F) with the aligning mark (J) and fix the intermediate lever screw (E) so that it contacts the control lever. [(K), (L)] 3. Adjustment of the FICD Insert the shim (L2) between the control lever (I) and the idle set screw (G). Fix with the adjusting screw to the position where the CSD lever (C) actuates the intermediate lever through the rod (D). (K), (L), (M) (O) timer stroke adjustment (mm) - (1): TA = -0.0437t + 1.99 (P) Lever angle (deg) - (2): Theta 1 = -0.0625 t + 5.65 (-20 deg C <= t <= 20 deg C) Theta 2 = -0.1108t + 6.62 (20 deg C =< t =< 60 deg C) (Q) lever position (mm) - (3): L1 = -0.02075t + 1.878 (-20 deg C <= t <= 20 deg C) L2 = -0.03900t + 2.277 (20 deg C =< t =< 60 deg C) The (Q) indicates the clearance between the control lever and the idle set screw. (R): cooling water temperature (deg C) (S): cooling water temperature: increase direction N:Pump speed X:Temperature t (deg C) Y1:Timer stroke TA (mm) Y2:Control lever position at theta L (deg, mm) (K): Fig. 1 (L): Fig. 2 (M): Fig. 3 (T): Timer piston stroke (mm) (U): Lever angle (deg) (W): Lever position (mm)
----------
L1=2.0+-0.05mm L2=L1+-0.05mm
----------
N1=500r/min a=20degC b=-20degC c=4.4+-1deg d=6.9+-3deg T1=1.1+-0.4mm T2=2.9+-0.6mm W1=1.5+-0.3mm W2=2.3+-1mm

Information:

START BY:a. remove alternator and mounting groupb. remove water temperature regulator and manifold1. Drain the coolant from the engine. 2. Loosen the clamps on breather tube (1), and pull it back for clearance. 3. Remove bolt (2) from the cover on the side of the cylinder block. 4. Remove the three bolts that hold cover (3) to the water pump. Remove cover (3) from the water pump. 5. Remove the two bolts, and remove elbow (4) from bonnet (5). Remove the two bolts, and remove bonnet (5) from the water pump. It is not necessary to remove bolts (6). These bolts only hold the cover to the timing gear cover.6. Remove six long bolts (7) that hold the water pump to the timing gear cover. Remove water pump (8).Install Water Pump
1. Check the O-ring seals and gaskets, and make replacements if needed. 2. Make sure O-ring seal (1) is in position on the water pump. Put water pump (2) into position in the timing gear cover. Install the bolts that hold the water pump in place. 3. Make sure the gaskets are in place. Connect bonnet (3) to the water pump. Connect elbow (4) to the bonnet. 4. Make sure O-ring seal (5) is in position, and install cover (6) on the water pump. 5. Install bolt (7) on the cover on the side of the engine. 6. Put breather tube (8) in position, and install the clamps that hold it.7. Fill the cooling system to the correct level. See the Maintenance Guide.Disassemble Water Pump
START BY:a. remove water pump The water pump seal can be replaced without removing the water pump from the engine.An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing.1. Remove O-ring seal (1) from the adapter.2. Remove adapter (2) from the housing. Remove the O-ring seal from the outside diameter of the adapter.3. Remove bolt (3) and the retainer that hold the impeller on the shaft. 4. Use tooling (A) to remove impeller (4) from the shaft. 5. Remove the spring and seal (5) from the shaft. 6. Remove four bolts (7) from retainer (6) that hold the shaft assembly to the pump housing.7. Remove O-ring seal (8) from the housing. 8. Remove gear and shaft assembly (10) from the housing.9. Remove bolt (9) and the retainer from the shaft assembly. 10. Use a press to remove the shaft assembly from gear (11). Remove the retainer from the shaft assembly. 11. Remove bearing (13), spacer (14) and bearing (12) from the shaft. 12. Remove lip-type seal (15) from the housing.13. Turn the housing over, and remove ceramic ring (16) and the seal.Assemble Water Pump
1. Use 6V1541 Quick Cure Primer and clean shaft