104740-8440 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047408440

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-8440 1047408440

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Cross reference number

ZEXEL 104740-8440 1047408440

Zexel num

Bosch num

Firm num

Name

104740-8440

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 750 750 750

Boost pressure kPa 44 42.7 45.3

Boost pressure mmHg 330 320 340

Average injection quantity mm3/st. 61.9 61.4 62.4

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. 63.1 62.6 63.6

Difference in delivery mm3/st. 5

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. 46.5 44 49

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. 61.9 60.9 62.9

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. 71.8 71.8 71.8

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. 68.7 66.2 71.2

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. 63.1 62.1 64.1

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. 62 60.5 63.5

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. 27.9 24.9 30.9

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2950 2950 2950

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. 27.9 22.9 32.9

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. 12.4 10.9 13.9

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. 12.4 10.4 14.4

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. 77 67 87

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. 77 67 87

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

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 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Overflow quantity cm3/min 410 280 540

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 412 383 441

Pressure kgf/cm2 4.2 3.9 4.5

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1000 1000 1000

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 1.5 1 2

Oil temperature degC 48 46 50

_03

Pump speed r/min 1000 1000 1000

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

_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 4.7 4.1 5.3

Oil temperature degC 50 48 52

_05

Pump speed r/min 1500 1500 1500

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 5.7 5.1 6.3

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 7.8 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 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 48 47.5 48.5

Timer stroke TA mm 3 2.8 3.2

Timer stroke variation dT mm 0.7 0.7 0.7

Basic *

Oil temperature degC 50 48 52

_02

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. 48 47 49

Timer stroke TA mm 3 2.6 3.4

Basic *

Oil temperature degC 50 48 52

_03

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. 38 37 39

Timer stroke TA mm 1.9 1.3 2.5

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

Control lever angle alpha deg. 59 55 63

Control lever angle beta deg. 42 37 47

Information:

Right Side (6 Cylinder Shown)(1) Depth that cup plugs are installed (measured from block face to top edge of plug) ... 1.25 0.25 mm (.049 .010 in)(2) Distance all sleeves extend from top face ... 14 2 mm (.55 .08 in)(3) Distance two large dowels extend from rear face ... 12.0 0.5 mm (.47 .02 in)(4) Distance two small dowels extend from rear face ... 8.0 0.5 mm (.31 .02 in)(5) Distance all dowels extend from front face ... 8.0 0.5 mm (.31 .02 in)
View A-A (Rear Face)(6) Bores in block for all camshaft bearings except front bearing ... 69.000 0.038 mm (2.7165 .0015 in)(7) Locate bearing oil hole for all camshaft bearings (except front bearing) at top of bore.
Front Face(8) Bore in block for front camshaft bearing ... 70.000 0.025 mm (2.7559 .0010 in)(9) Front camshaft bearing joint location.(10) Front camshaft bearing oil hole. Install front camshaft bearing with bearing oil hole (10) aligned with oil hole in block and bearing joint (9) positioned as shown.(11) Width of main bearing cap ... 159.995 0.020 mm (6.2990 .0008 in) Width of cylinder block for main bearing cap ... 160.000 0.018 mm (6.2992 .0007 in)(12) Bore in block for main bearings ... 95.000 0.013 mm (3.7402 .0005 in)(13) Main bearing cap bolts. Install as follows: Install bearing caps with sequence number to the right, 1 through 5 (for 4 cylinder) or 1 through 7 (for 6 cylinder), front to rear.a. Before assembly, put 2P2506 Thread Lubricant on the bolt threads and washer face.b. Tighten both bolts of each bearing cap to a torque of ... 54 7 N m (40 5 lb ft)c. Then tighten bolts an additional ... 90 5 degrees (1/4 turn)(14) Location of bearing cap sequence number.(15) Dimension from centerline of crankshaft bore to pan rail ... 110.00 mm (4.331 in)(16) Dimension from centerline of crankshaft bore to top of block ... 322.00 .017 mm (12.677 .0007 in)(17) Cylinder bore size ... 105.025 .025 mm (4.1348 .0010 in) Bore size must be checked with a 4C4377 Cylinder Head Stress Plate and gasket installed. Refer to Installation Of 7C6208 Cylinder Sleeve, Special Instruction Form No. SEHS9047. (18) Piston cooling jet. Check piston cooling jets by inserting a 1.3 mm (.05 in) diameter drill rod into jet. Rod must pass through a 5.0 mm (.20 in) diameter circle in location (A) and a 13 mm (.51 in) diameter circle in location (B). Dimension (C) is 25.9 mm (1.02 in). Dimension (D) is 33.4 mm (1.31 in). Dimension (E) is 26.95 mm (1.061 in). Dimension (F) is 9.8 mm (.39 in). Dimension (G) is 50 mm (2.0 in). Distance four sleeves (19) extend from side face ... 5.0 0.5 mm (.20 .02 in)