104740-2491 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047402491

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-2491 1047402491

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Cross reference number

ZEXEL 104740-2491 1047402491

Zexel num

Bosch num

Firm num

Name

104740-2491

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 OFF. OFF

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 40 38.7 41.3

Boost pressure mmHg 300 290 310

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 40 38.7 41.3

Boost pressure mmHg 300 290 310

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 35.5 39.5

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. 21.4 13.4 29.4

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. 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 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 ON 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 353 324 382

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

Pressure with S/T OFF kPa 412 383 441

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

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

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 OFF kPa 343 304 382

Pressure with S/T OFF 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 OFF kPa 411.5 382 441

Pressure with S/T OFF 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 OFF kPa 520 481 559

Pressure with S/T OFF 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 OFF kPa 696 647 745

Pressure with S/T OFF 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 1 0.5 1.5

Timer stroke with S/T OFF mm 2.2 2 2.4

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_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 OFF 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 1 0.4 1.6

Timer stroke with S/T OFF mm 2.2 1.9 2.5

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 OFF 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 OFF 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=17.0+-1.0mm3/st V1=3.86+-0.03V V2=(1.34+-0.4V) V3=(8.34+-1.47V) C1=(15.1deg) C2=0deg C3=42+-5deg Vi=10V C4=(5+-3deg) C5=(21.5++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=0.82--mm 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=0.82--mm L3=11.0+-0.05mm

Information:

Start By:a. remove valve covers 1. Loosen the fuel injection line nut at the nozzle end with tool (A).2. Loosen the fuel line nut at the fuel injection line adapter with tool (B). Remove inner fuel injection lines (1). Install caps and plugs on all fuel line openings to keep dirt out of the fuel system. If necessary, use tooling (D) to turn the engine so the valves do not make contact with the pistons when the valves are opened with tool (C) to remove the push rods.3. Put compression on the valve springs with tool (C), and remove push rods (2). Put identification marks on the push rods as to their location in the engine.4. Push the push rod end of the rocker arms down. 5. Remove the intake valve lifter with tooling (E) as follows:a. Install 5P2685 Nut (3) and 5P6601 Collet (4) on 5P2408 Outer Handle Assembly (5).b. Install 5P6599 Inner Handle Assembly (6) in 5P2408 Outer Handle Assembly (5). c. Install tooling (E) in the intake valve lifter. Hold the 5P2408 Outer Handle Assembly, and tighten the 5P6599 Inner Handle Assembly until the 5P6601 Collet is tight against the inside of the intake valve lifter. d. Remove intake valve lifters (7) from the cylinder block with tooling (E). Put identification marks on the lifters as to their location in the engine. 6. Remove the exhaust valve lifters with tooling (E) as follows:a. Install 5P2685 Nut (3) and 5P6601 Collet (4) on 5P2408 Outer Handle Assembly (5). The opening in the cylinder head assembly for the intake valve lifter is larger than the opening in the exhaust valve lifter side. The tooling and each valve lifter must be installed and removed from the intake valve lifter side.b. Install the outer handle assembly in the intake valve lifter side of the cylinder head assembly. Slide the flat area of 5P2408 Outer Handle Assembly (5) through the head casting, and install the 5P6601 Collet in the exhaust valve lifters. c. Install 5P6599 Inner Handle Assembly (6) in 5P2408 Outer Handle Assembly (5). Hold the 5P2408 Handle Assembly, and tighten the 5P6599 Handle Assembly until the 5P6601 Collet is tight against the inside of the exhaust valve lifter.d. Pull the exhaust valve lifter up until the spring on the exhaust valve lifter is free from the cylinder block.e. Remove the 5P6599 Inner Handle Assembly. Slide the 5P2408 Outer Handle Assembly through the head casting, and remove it from the intake valve lifter side of the cylinder head. f. Use a magnet, and remove exhaust valve lifters (8) from the intake valve lifter side of the cylinder head assembly. Put identification marks on the lifters as to their location in the engine.7. Remove the guide springs from the lifters.Install Valve Lifters
Steps 1 and 2 must be done to install intake or exhaust valve lifters.
Make sure guide spring (9) is not damaged or worn. If the guide spring is damaged or worn, replace the guide spring. See Guideline For Reusable