104742-7040 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047427040

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104742-7040 1047427040

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Cross reference number

ZEXEL 104742-7040 1047427040

Zexel num

Bosch num

Firm num

Name

104742-7040

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

Timer measuring device installation position
High pressure side HIGH PRESSURE SIDE

Injection timing adjustment

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 47.3 46.8 47.8

Difference in delivery mm3/st. 3

Basic *

Injection timing adjustment_02

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 26.7 23.2 30.2

Injection timing adjustment_03

Pump speed r/min 1225 1225 1225

Average injection quantity mm3/st. 48.8 46.3 51.3

Injection timing adjustment_04

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 47.3 46.3 48.3

Injection timing adjustment_05

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 43.9 41.4 46.4

Injection quantity adjustment

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 26.7 23.7 29.7

Difference in delivery mm3/st. 4.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 3

Governor adjustment

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 11.2 9.2 13.2

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 3

Governor adjustment_03

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 11.2 8.7 13.7

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 58 53 63

Basic *

Remarks
Full

Speed control lever angle

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 900 900 900

Overflow quantity cm3/min 459 330 588

Stop lever angle

Pump speed r/min 900 900 900

Pressure kPa 500.5 481 520

Pressure kgf/cm2 5.1 4.9 5.3

Basic *

Stop lever angle_02

Pump speed r/min 900 900 900

Pressure kPa 500.5 481 520

Pressure kgf/cm2 5.1 4.9 5.3

Stop lever angle_03

Pump speed r/min 1225 1225 1225

Pressure kPa 578.5 549 608

Pressure kgf/cm2 5.9 5.6 6.2

0000001101

Pump speed r/min 900 900 900

Timer stroke mm 4.8 4.6 5

Basic *

_02

Pump speed r/min 500 500 500

Timer stroke mm 1.8 1.2 2.4

_03

Pump speed r/min 900 900 900

Timer stroke mm 4.8 4.5 5.1

_04

Pump speed r/min 1225 1225 1225

Timer stroke mm 6.7 6.3 7.1

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 31 30.5 31.5

Timer stroke variation dT mm 0.8 0.6 1

Basic *

_02

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 31 30 32

Timer stroke variation dT mm 0.8 0.5 1.1

_03

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 22 20.5 23.5

Timer stroke variation dT mm 1.6 1.3 1.9

Timing setting

K dimension mm 3.1 3 3.2

KF dimension mm 5 4.9 5.1

MS dimension mm 0.9 0.8 1

Control lever angle alpha deg. 16 12 20

Control lever angle beta deg. 35 30 40

Test data Ex:

0000001801 STARTING I/Q ADJUSTMENT

Starting injection quantity adjustment Adjust the adjusting bolt A so that the starting injection quantity adjustment is within the standards. Fix using nut (B).
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L=7.4~11.1mm T=6~9N-m(0.6~0.9kgf-m)

Information:

Start By:a. remove oil pumpb. remove oil pan plate 1. Turn the crankshaft until two pistons are at the bottom center. Remove connecting rod caps (1) from the two connecting rods. Remove the lower half of the rod bearing from the rod bearing cap.2. Push the connecting rods away from the crankshaft. Remove the upper half of the rod bearing from the connecting rod. Install the connecting rod bearings dry when the clearance checks are made. Put clean engine oil on the connecting rod bearings for final assembly.3. Install the upper half of the rod bearing in the connecting rod.4. Install the lower half of the rod bearing in the connecting rod cap. Be sure the tabs in the back of the connecting rod bearings are in the tab grooves of the connecting rod and cap. 5. Use Plastigage (A) to check the connecting rod bearing clearance.6. Put Plastigage (A) on the connecting rod bearing.7. Put 2P2506 Thread Lubricant on the threads of the rod bolts and seat surfaces of the nuts.
When connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
Do not turn the crankshaft when Plastigage (A) is in position.
Do not use an impact wrench to tighten the nuts the additional 90°.
8. Install connecting rod cap (1). Install the nuts. Tighten the nuts to a torque of 40 4 N m (30 3 lb ft). Put a mark on each nut and the end of each bolt. Tighten the nuts 90° more. Remove the connecting rod caps. Remove Plastigage (A) and measure the width of the Plastigage. The connecting rod clearance must be 0.076 to 0.168 mm (.0030 to .0066 in) for new bearings. The maximum clearance with used bearings is 0.25 mm (.010 in).9. Install the connecting rod caps and tighten the nuts as in Step 8.10. Do Steps 1 through 9 for the remainder of the connecting rod bearings.End By:a. install oil pan plateb. install oil pump