104740-2490 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047402490

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-2490 1047402490

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Cross reference number

ZEXEL 104740-2490 1047402490

Zexel num

Bosch num

Firm num

Name

104740-2490

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

(Solenoid timer adjustment condition)
With S/T O-ring; S/T ON. ON

Injection timing 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. 33.5 33.1 33.9

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_02

Pump speed r/min 900 900 900

Boost pressure kPa 44 42.7 45.3

Boost pressure mmHg 330 320 340

Average injection quantity mm3/st. 45 44.6 45.4

Difference in delivery mm3/st. 3

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. 38.2 33.7 42.7

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. 33.4 30.9 35.9

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 700 700 700

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 33.5 32.5 34.5

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_06

Pump speed r/min 900 900 900

Boost pressure kPa 44 42.7 45.3

Boost pressure mmHg 330 320 340

Average injection quantity mm3/st. 45 44 46

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_07

Pump speed r/min 1200 1200 1200

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 54.8 51.8 57.8

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. 52.6 49.6 55.6

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 44.5 51.5

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. 45.6 42.1 49.1

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2550 2550 2550

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 37.5 36.5 38.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2550 2550 2550

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 37.5 35 40

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_03

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. 23.9 16.4 31.4

Difference in delivery mm3/st. 5.5

Oil temperature degC 55 52 58

Injection quantity adjustment_04

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. 7.5

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 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5

Oil temperature degC 50 48 52

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. 68 63 73

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. 68 63 73

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 with S/T OFF cm3/min 380 250 510

Oil temperature degC 50 48 52

Remarks
MEASURE

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 with S/T ON kPa 412 392 432

Pressure with S/T ON kgf/cm2 4.2 4 4.4

Pressure with S/T OFF kPa 353 324 382

Pressure with S/T OFF kgf/cm2 3.6 3.3 3.9

Basic *

Oil temperature degC 50 48 52

Remarks
ON

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 with S/T ON kPa 343 304 382

Pressure with S/T ON kgf/cm2 3.5 3.1 3.9

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 with S/T ON kPa 411.5 382 441

Pressure with S/T ON kgf/cm2 4.2 3.9 4.5

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 with S/T ON kPa 520 481 559

Pressure with S/T ON kgf/cm2 5.3 4.9 5.7

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 with S/T ON kPa 696 647 745

Pressure with S/T ON kgf/cm2 7.1 6.6 7.6

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 with S/T ON mm 2.2 2 2.4

Timer stroke with S/T OFF mm 1 0.5 1.5

Basic *

Oil temperature degC 50 48 52

Remarks
ON

_02

Pump speed r/min 600 600 600

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke with S/T ON mm 0.7

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 with S/T ON mm 2.2 1.9 2.5

Timer stroke with S/T OFF mm 1 0.4 1.6

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 with S/T ON mm 5.1 4.7 5.5

Oil temperature degC 50 48 52

_05

Pump speed r/min 2200 2200 2200

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke with S/T ON mm 8.15 7.7 8.6

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 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 21 29

Control lever angle beta deg. 42 37 47

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Potentiometer adjustment (dummy bolt type) N:Pump speed Q:Injection quantity V:Output voltage Vi:Applied voltage A:Standard point B:Check. C/L: control lever angle I:Idling lever position F:Full speed lever position E:Conversion point C:Lever position G:From idle H:ON-->OFF M:OFF-->ON J:Connecting diagram for the potentiometer K:Output O:Output when (2) and (3) connected. P:When (4) or (6) connected: switch OFF to ON. R:When (4) or (5) connected: switch ON to OFF.
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N1=700r/min Q1=15.9+-1.0mm3/st V1=2.83+-0.03V V2=(1.02+-0.4V) V3=(8.02+-1.47V) C1=(10.8deg) C2=0deg C3=42+-5deg Vi=10V C4=(7.5+-3deg) C5=(24.0++deg)

0000001901 STARTING I/Q ADJUSTMENT

Starting injection quantity adjustment Adjust adjusting bolt so that the starting injection quantity is within the standard. Fix using nut. (A): Lock nut. (B): Stopping lever (C): Adjustment bolt
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L=5.9~8.2mm

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 idling position. (2)With intermediate lever (D) and bracket (K)'s stopper contacting, fix nut (B) at the position where the clearance between the intermediate lever screw (A) and the control lever (C) is L1. 2. Fixing the stopper (I) (1)Pull the CSD lever F in the direction X until it contacts the stopper I. (2)With these types of timers, tighten the socket head bolt (J) at the position where the advance angle is L2. 3. Screw (G) adjustment (1)Pull the CSD lever F in the direction X until it contacts the stopper I and adjust using screw G so that the control lever shim thickness is L3. Then fix using nut H. Pin E is fully above the elongated hole (R). (2)When the CSD lever (F) is returned, there can be a clearance between (E)'s pin and (D)'s intermediate lever. Also, to fine adjust the lever position, use screw (A) (but you must maintain clearance L1).
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L1=1~2mm L2=1.64+-0.2mm L3=11.0+-0.05mm R=45.5mm
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T1=6~9N-m(0.6~0.9kgf-m) T2=4.9~7N-m(0.5~0.7kgf-m) T3=2~2.9N-m(0.2~0.3kgf-m) R=45.5mm L1=1~2mm L2=1.64+-0.2mm L3=11.0+-0.05mm

Information:

Start By:a. remove valve covers 1. Remove bolts (1) that hold the valve cover bases to the cylinder head assembly. Remove valve cover bases (2). 2. Use tool (A) to loosen fuel injection line (3) from fuel injection nozzle (4). 3. Use tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (3). Install caps and plugs on all fuel injection line openings to keep dirt out of the fuel system. 4. Remove bolts (5) that hold the rocker shaft assemblies to the cylinder head assembly.5. Remove rocker shaft assemblies (6). 6. Put identification marks on the push rods as to their location in the engine. Remove push rods (7). 7. Put identification marks on the bridges as to their location in the engine. Remove bridges (8) from the dowels on the cylinder head assembly.Install Rocker Shaft Assemblies And Push Rods
1. Put clean engine oil on the bridges and dowels. Install the original bridges in their respective locations. New bridges can be mixed.2. Install bridges (8) on the bridge dowels. While firmly pressing 0.5 to 4.5 kg (1 to 10 lb.) straight down on the top contact surface of the bridge, turn the adjusting screw clockwise until contact is made with the valve stem. Turn the screw an additional 20 ° to 30 ° (1/3 to 1/2 of 1 hex on nut). This will straighten the dowel in the guide and compensate for the slack in the threads. Hold the adjusting screw in this position, and tighten the locknut to a torque of 30 4 N m (22 3 lb.ft.). Install original push rods in their respective locations in the engine. New push rods can be mixed.3. Install push rods (7). 4. Put rocker shaft assemblies (6) in position on the cylinder head assembly.5. Put clean engine oil on the threads of bolts (5) that hold the shaft assemblies in place. Tighten the bolts first to a torque of 270 25 N m (200 18 lb.ft.). Start with the bolt in the center of the rocker shaft assembly. Tighten the bolts again to a torque of 450 20 N m (330 15 lb.ft.). Tighten the bolts again by hand to a torque of 450 20 N m (330 15 lb.ft.).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (3). Tighten the fuel injection line adapter nuts (9) to a torque of 40 7 N m (30 5 lb.ft.) with tool (B).7. Tighten fuel injection line nut (10) to a torque of 40 7 N m (30 5 lb.ft.) with tool (A).8. Make adjustments to the valves until the intake valve clearance is 0.38 mm (.015 in.) and the exhaust valve clearance is 0.76 mm (.030 in.). See Valve Clearance Setting in Testing And Adjusting. Tighten the locknut to a torque of 30 4 N m (22 3