104742-7250 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047427250

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104742-7250 1047427250

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Cross reference number

ZEXEL 104742-7250 1047427250

Zexel num

Bosch num

Firm num

Name

104742-7250

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 1600 1600 1600

Average injection quantity mm3/st. 67.6 67.1 68.1

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 47.5 41.5 53.5

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 45.6 39.6 51.6

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 54.1 49.6 58.6

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 70.4 66.4 74.4

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 67.6 66.6 68.6

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 64.3 60.3 68.3

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2050 2050 2050

Average injection quantity mm3/st. 7.3 4.3 10.3

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2200 2200 2200

Average injection quantity mm3/st. 3

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2050 2050 2050

Average injection quantity mm3/st. 7.3 2.8 11.8

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 17.2 15.2 19.2

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 17.2 14.7 19.7

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 65 105

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 85 65 105

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_03

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 65 105

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet ON at idling position and reversed operate

Speed control lever angle_02

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet ON at idling position and reversed operate

Speed control lever angle_03

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position and stop lever operate

Speed control lever angle_04

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position and stop lever operate

0000000901

Pump speed r/min 1050 1050 1050

Overflow quantity cm3/min 1280 1050 1510

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1050 1050 1050

Pressure kPa 510 481 539

Pressure kgf/cm2 5.2 4.9 5.5

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 950 950 950

Pressure kPa 490 451 529

Pressure kgf/cm2 5 4.6 5.4

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1050 1050 1050

Pressure kPa 510 471 549

Pressure kgf/cm2 5.2 4.8 5.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1800 1800 1800

Pressure kPa 677 638 716

Pressure kgf/cm2 6.9 6.5 7.3

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1050 1050 1050

Timer stroke mm 0.8 0.6 1

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1050 1050 1050

Timer stroke mm 0.8 0.4 1.2

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1800 1800 1800

Timer stroke mm 1.7 1.2 2.1

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 16 16 16

Test voltage
Reverse operation (At Normal: OFF, At Stop: ON) V 25 24 26

Timing setting

K dimension mm 3.6 3.5 3.7

KF dimension mm 5.54 5.44 5.64

MS dimension mm 0.9 0.8 1

Pre-stroke mm 0.2 0.18 0.22

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 43.5 38.5 48.5

Test data Ex:

0000001801 Temp. adjust full-load screw

Temporary full load screw adjustment Set the full load screw protrusion at L mm at assembly.
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L=14+-0.5mm
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L=14+-0.5mm

0000001901 STOP LEVER ADJUSTMENT

Adjustment of the stop lever 1. Confirm that the starting injection quantity is within standards at the normal position. If below the specified lower limit, move the stop lever serrations one tooth and reconfirm. 2. Pull the stop lever (A) to the fuel cut direction at the standard idling speed of N and adjust the screw (B) to the position Q. Fix nut (C) to the torque T at the position where the clearance between the stop lever and the end of the screw is L mm (the screw is returned 2 turns). The head of the screw must protrude above the face of the nut. If the head of the screw is below the face of the nut, adjust the clearance between the stop lever A and the end of the screw at Q to L mm or more. 3. If adjustment in item 2 is not possible, move the stop lever installation position 1 tooth. 4. The stop lever's operating force is max. M kg (at R = 35). The stop lever must operate smoothly. (D) Normal position (E) Stop position
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N=325r/min Q=0mm3/st T=6~9N-m(0.6~0.9kgf-m) L=2mm M=4.0kg
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S=Dia6.5+0.09mm R=35mm

Information:

(1) Cylinder head bolts and nuts tightening procedure:1. Put engine oil on the threads of bolts and nuts. Tighten all bolts and nuts in number sequence to a torque of ... 45 N m (35 lb ft)2. Tighten all bolts and nuts in number sequence to a torque of ... 95 N m (70 lb ft)3. Again tighten all bolts and nuts in number sequence to a final torque of ... 135 N m (100 lb ft).Retighten the cylinder head bolts and nuts after the engine has run under partial load for approximately thirty minutes. The rocker shaft assembly has to be removed and valve lash adjusted again.a. If the bolts and nuts move before the correct final torque is reached, retighten everything in the sequence again to the final torque of 135 N m (100 lb ft).b. If the bolts and nuts do not move before the correct final torque is reached, back each one off 30 to 60° (with an 8T3052 Degree Wheel) and retighten again, in the sequence shown, to the final torque. After all the bolts and nuts are retightened, check the first 10 positions to make sure they are tightened to the correct torque.c. After 25 to 50 hours of service for a new or rebuilt engine, retorque the cylinder head bolts as shown in Step a above and adjust the valves again.New cylinder blocks have been introduced on the 4.236 engine. The new cylinder blocks have deeper cylinder head bolt holes and longer bolts. The old and new sizes are shown. The change became effective at engine serial number LD----U027631M and up. See General Information in Systems Operation for the engine serial number location. The new cylinder head bolts are not interchangeable between old and new bolts.(2) Torque for nuts that hold injectors ... 19 N m (14 lb ft)Replace the copper washer and rubber seal between the head and the injector every time the injector is removed. See Fuel Injector Installation in Testing And Adjusting.(3) Torque for fuel line nuts ... 20 N m (15 lb ft)(4) Torque for nuts that hold rocker shaft to head ... 75 N m (54 lb ft)(5) Valve lash [clearance (cold)], between rocker arm and valve: Intake ... 0.30 mm (0.012 in)Exhaust ... 0.30 mm (0.012 in)(6) Maximum permissible nozzle projection below cylinder head face after resurfacing ... 4.44 mm (0.175 in) Resurfacing allowance (maximum) ... 0.30 mm (0.012 in)(7) Depth of cylinder head (new) ... 103.188 0.38 mm (4.0625 0.015 in) Minimum depth of cylinder head (after resurfacing) ... 102.502 mm (4.0355 in)Maximum permissible amount of bow (curve of cylinder head):Across width (transverse) ... 0.09 mm (0.003 in)Across length (longitudinal) ... 0.15 mm (0.006 in)(See Cylinder Head Check in Testing And Adjusting)