104740-8170 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047408170

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-8170 1047408170

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Cross reference number

ZEXEL 104740-8170 1047408170

Zexel num

Bosch num

Firm num

Name

104740-8170

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 750 750 750

Boost pressure kPa 44 42.7 45.3

Boost pressure mmHg 330 320 340

Average injection quantity mm3/st. 64.8 64.3 65.3

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 65.5 65 66

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing 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. 46 43.5 48.5

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 44 42.7 45.3

Boost pressure mmHg 330 320 340

Average injection quantity mm3/st. 64.8 63.8 65.8

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_05

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 73 73 73

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 69.2 66.7 71.7

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 65.5 64.5 66.5

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_08

Pump speed r/min 2100 2100 2100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 63.8 62.3 65.3

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2650 2650 2650

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 25 22 28

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 3050 3050 3050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2650 2650 2650

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 25 20 30

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12 10.5 13.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12 10 14

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

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. 63 63 83

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. 63 63 83

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 375 375 375

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 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Overflow quantity cm3/min 420 290 550

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 471 442 500

Pressure kgf/cm2 4.8 4.5 5.1

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 600 600 600

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 314 275 353

Pressure kgf/cm2 3.2 2.8 3.6

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 471 432 510

Pressure kgf/cm2 4.8 4.4 5.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2100 2100 2100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 667 628 706

Pressure kgf/cm2 6.8 6.4 7.2

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 3.7 3.5 3.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 500 500 500

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 1.2 0.6 1.8

Oil temperature degC 48 46 50

_03

Pump speed r/min 750 750 750

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 2 1.4 2.6

Oil temperature degC 50 48 52

_04

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 3.7 3.3 4.1

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 1750 1750 1750

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 5.8 5.2 6.4

Oil temperature degC 50 48 52

_06

Pump speed r/min 2100 2100 2100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 7.2 6.6 7.8

Oil temperature degC 52 50 54

_07

Pump speed r/min 2250 2250 2250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 7.8 7.4 8.2

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 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 53 52.5 53.5

Timer stroke TA mm 3.1 3.1 3.1

Timer stroke variation dT mm 0.6 0.4 0.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 53 52 54

Timer stroke variation dT mm 0.6 0.2 1

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 40 39 41

Timer stroke variation dT mm 1.4 0.9 1.9

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 0.7 0.6 0.8

BCS stroke mm 6.5 6.4 6.6

Control lever angle alpha deg. 59 55 63

Control lever angle beta deg. 42 37 47

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Dummy bolt method 1. Hold the dummy bolt against the control lever at position N = N1 and Q = Q1 and fix using the lock nut. 2. At potentiometer adjustment, with the control lever contacting the dummy bolt, adjust the potentiometer so that the output voltage is V1. 3. After adjustment, remove the dummy bolt and confirm that the potentiometer output voltage at the control lever's idling and full speed positions is as specified above. N:Pump speed P:Boost pressure Q:Injection quantity V:Output voltage A:Adjusting point B:Checking point C/L: control lever position I:Idling F:Full speed Vi:Applied voltage
----------

----------
N1=750(r/min) V1=5+-0.03(V) V2=1++(V) V3=(8.6(V)) Q1=35.5+-1(mm3/st) Vi=10(V)

0000001901 V-FICD ADJUSTMENT

Adjustment of the two stage actuator (FICD). 1. Install the 2-stage actuator on the injection pump. 2. With the control lever in the idle position adjust using the rod position adjusting nut so that the clearance between control lever and the rod is L1. 3. After adjusting the potentiometer, fix the control lever so that the potentiometer output voltage is V1. (Applied voltage Vi) 4. Adjust the position of A so that the actuator stroke is the full stroke, then fix using nut (B). (C) Rod position adjusting nut (D) Stroke adjusting nut (E) Actuator stroke
----------
L1=1+1(mm) V1=3.5+-0.03(V) Vi=10(V)
----------
L1=1+1(mm) SW1=SW7 SW2=SW8 T1=1.4~2.0(Nm)(0.14~0.2(kgfm)) T2=3.4~4.9(Nm)(0.35~0.5(kgfm))

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