104740-2370 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047402370

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-2370 1047402370

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Cross reference number

ZEXEL 104740-2370 1047402370

Zexel num

Bosch num

Firm num

Name

104740-2370

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)
Left L

Injection timing adjustment

Pump speed r/min 800 800 800

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 32 31.6 32.4

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_02

Pump speed r/min 900 900 900

Boost pressure kPa 43.3 42 44.6

Boost pressure mmHg 325 315 335

Average injection quantity mm3/st. 45.1 44.7 45.5

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 40.9 36.4 45.4

Oil temperature degC 48 46 50

Injection timing adjustment_04

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 35.7 33.7 37.7

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 800 800 800

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 32 31 33

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_06

Pump speed r/min 900 900 900

Boost pressure kPa 43.3 42 44.6

Boost pressure mmHg 325 315 335

Average injection quantity mm3/st. 45.1 44.1 46.1

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_07

Pump speed r/min 1400 1400 1400

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 51.6 49.6 53.6

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 1800 1800 1800

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 51.7 49.7 53.7

Oil temperature degC 50 48 52

Injection timing adjustment_09

Pump speed r/min 2200 2200 2200

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 48.3 45.3 51.3

Oil temperature degC 52 50 54

Injection timing adjustment_10

Pump speed r/min 2400 2400 2400

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 46.2 42.7 49.7

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 19.5 17.5 21.5

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 19.5 16 23

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2950 2950 2950

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 6

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10.5 9.5 11.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10.5 8.5 12.5

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 800 800 800

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

Oil temperature degC 50 48 52

Boost compensator adjustment

Pump speed r/min 700 700 700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 15.9 9.4 22.4

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 5.8 5.8 5.8

Remarks
From idle

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 11.3 4.3 18.3

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 5.8 5.8 5.8

Remarks
From idle

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 67 62 72

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 67 62 72

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_03

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 67 62 72

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 900 900 900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Overflow quantity cm3/min 380 250 510

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 900 900 900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure kPa 382 353 411

Pressure kgf/cm2 3.9 3.6 4.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 600 600 600

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure kPa 323.5 284 363

Pressure kgf/cm2 3.3 2.9 3.7

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 900 900 900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure kPa 382.5 343 422

Pressure kgf/cm2 3.9 3.5 4.3

Basic *

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1400 1400 1400

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure kPa 490.5 451 530

Pressure kgf/cm2 5 4.6 5.4

Oil temperature degC 50 48 52

Stop lever angle_05

Pump speed r/min 2200 2200 2200

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure kPa 657 608 706

Pressure kgf/cm2 6.7 6.2 7.2

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 900 900 900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke mm 3 2.8 3.2

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 600 600 600

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke mm 1 0.4 1.6

Oil temperature degC 50 48 52

_03

Pump speed r/min 900 900 900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke mm 3 2.7 3.3

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1400 1400 1400

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke mm 5.9 5.5 6.3

Oil temperature degC 50 48 52

_05

Pump speed r/min 1800 1800 1800

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke mm 8.2 7.7 8.7

Oil temperature degC 50 48 52

_06

Pump speed r/min 2200 2200 2200

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke mm 8.95 8.5 9.4

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 900 900 900

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 23.5 22.5 24.5

Timer stroke TA mm 2.7 2.7 2.7

Timer stroke variation dT mm 0.3 0.1 0.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 23.5 22 25

Timer stroke TA mm 2.7 2.3 3.1

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 6.29 6.19 6.39

MS dimension mm 0.9 0.8 1

BCS stroke mm 4.6 4.4 4.8

Control lever angle alpha deg. 25 23 27

Control lever angle beta deg. 42 37 47

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer At pump speed N and with the control lever angle at a from the idle position (clearance L), convert the injection quantity obtained to a voltage value using the graph and adjust the potentiometer. V:Output voltage Q:Injection quantity A:Performance standards C:Position of the control lever C1:Idle C2:Full speed E:Standards for the potentiometer's ON - OFF switch B:Conversion point B1:OFF-->ON B2:OFF-->ON D:Lever opening (from idle) K = formula V+-0.03 = 0.071693Q+1.81172 Q <= 11.7 (mm3/st) V+-0.03 = 0.0416286Q + 2.16366 Q>11.7 (mm3/st) Vi:Applied voltage X:Injection quantity (mm3/st) Y:Voltage (V) M:Connecting diagram for the potentiometer J:Output G:Output when (2) and (3) connected. H:When (4) or (6) connected: switch OFF to ON. I:When (4) or (5) connected: switch ON to OFF.
----------
N=700r/min a=9deg L=5.8mm Vi=10V
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V1=0.5++V V2=9.6--V D1=5+-3deg D2=21.5++deg

0000001901 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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D=6.0~8.7mm

0000002001 M-CSD ADJUSTMENT

M-CSD adjustment 1. Fixing intermediate lever screw (A) [roller (E) must not contact intermediate lever (D)] (1)Hold the control lever (C) in the idle position. (2)Insert a block gauge (thickness gauge) L1 between the intermediate lever (D) and the bracket (K). Adjust screw (A) so that the distance between screw A and the control lever to L2 and fix using the nut (B). 2. Fixing the M-CSD stopper (I) Pull the CSD lever F in the direction X until it contacts the stopper I and tighten the socket head bolt J when the timer stroke is L3. 3. Screw (G) adjustment (1)Adjust using the screw G so that the roller E contacts the intermediate lever D, then fix using the nut H. (2)Pull the CSD lever F in the direction X until it contacts the stopper I and confirm that the control lever shim thickness (lever position) is L4. Note: Use screw (A) to fine-adjust the lever position. [Maintain a gap L2 between the screw (A) and the control lever (C).]
----------
L1=1+-0.1mm L2=1~2mm L3=0.82+-0.2mm L4=5.2+-0.5mm
----------
L1=1+-0.1mm L2=1~2mm L4=5.2+-0.5mm T1=5.9~8.8N-m(0.6~0.9kgf-m) T2=4.9~6.9N-m(0.5~0.7kgf-m) T3=2.0~2.9N-m(0.2~0.3kgf-m)

Information:

Start By:a. remove automatic timing advance unit
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
Before any timing gears are removed, make sure "C" on the crankshaft gear is in alignment with "C" mark on the camshaft gear. 1. Remove bolts, plate (1) and fuel pump idler gear (2). 2. Remove bearing from idler gear (2) with tool (A). 3. Remove four bolts (3) and camshaft gear (4). 4. Remove bolts that are used to fasten shield (5) in position between the fuel pump and the exhaust manifold. Slide shield back from the timing cover plate.5. Remove the three nuts (6). 6. Remove six bolts (7). Remove the timing gear plate and the gasket. The following steps are to install the timing gears and plate.7. Clean the old gasket from the contact surfaces of the timing gear plate and cylinder block. Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block.8. Be sure the O-ring seals are in position on the end of the fuel injection pump housing. Put the timing gear plate in position on the cylinder block and install the six bolts (7). Install nuts (6).
After the timing gear plate is installed, be sure the rack is free to move in the fuel injection pump housing. The O-ring seal on the drive end of the fuel injection pump housing can hold the rack and prevent free rack movement. Rack movement can be seen through hole in the timing gear plate just above where the fuel pump gear is mounted. If the rack does not move freely, remove the timing gear plate and check the O-ring seal on the drive end of the fuel injection pump housing. If the rack does not move freely, the engine can over speed and be damaged. Serious personal injury can be the result.
9. Install camshaft gear (4) with the "C" mark on the camshaft gear in alignment with the "C" mark on the crankshaft gear as shown in the illustration in the Specification section of this manual. Tighten the volts to a torque of 55 7 N m (41 5 lb ft).10. Use tooling (A) to install the bearing in idler gear (2). The end of the bearing must be 1.52 .025 mm (.060 .010 in) below the face of the gear hub.11. Be sure the oil hole in the shaft for gear (2) is open. Install idler gear (2). Put the plate on position with the finished side toward gear (2) and install the bolts.12. Install shield (5) and the four bolts.End By:a. install automatic timing advance unit