104745-9320 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047459320

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104745-9320 1047459320

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Cross reference number

ZEXEL 104745-9320 1047459320

Zexel num

Bosch num

Firm num

Name

104745-9320

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 1100 1100 1100

Average injection quantity mm3/st. 49.9 49.4 50.4

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 43.8 41.3 46.3

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 52.4 51.4 53.4

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2150 2150 2150

Average injection quantity mm3/st. 48.8 46.3 51.3

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2550 2550 2550

Average injection quantity mm3/st. 10.9 8.9 12.9

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 35.6 35.6 35.6

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2550 2550 2550

Average injection quantity mm3/st. 10.9 8.4 13.4

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 7.7 5.7 9.7

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 7.7 5.2 10.2

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 45 80

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 45 80

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 350 350 350

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 1100 1100 1100

Overflow quantity cm3/min 390 260 520

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1100 1100 1100

Pressure kPa 431 402 460

Pressure kgf/cm2 4.4 4.1 4.7

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1100 1100 1100

Pressure kPa 431 392 470

Pressure kgf/cm2 4.4 4 4.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1700 1700 1700

Pressure kPa 559 520 598

Pressure kgf/cm2 5.7 5.3 6.1

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1100 1100 1100

Timer stroke mm 1.9 1.7 2.1

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 850 850 850

Timer stroke mm 0.5 0 1

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Timer stroke mm 1.9 1.6 2.2

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1700 1700 1700

Timer stroke mm 4.4 3.9 4.9

Oil temperature degC 50 48 52

_05

Pump speed r/min 2300 2300 2300

Timer stroke mm 6.1 5.6 6.5

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 1100 1100 1100

Average injection quantity mm3/st. 31 30.5 31.5

Timer stroke TA mm 1.2 1 1.4

Timer stroke variation dT mm 0.7 0.7 0.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 31 30 32

Timer stroke TA mm 1.2 0.9 1.5

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 22 19.5 24.5

Timer stroke TA mm 0.6 0.1 1.1

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 0.9 0.8 1

Pre-stroke mm 0.1 0.08 0.12

Control lever angle alpha deg. 25 23 27

Control lever angle beta deg. 36 31 41

Information:

MOVING WATER SLEEVES
1. 8S6692 Water Sleeve Tool.5. Disconnect oil cooler water outlet elbow at back side of timing gear cover.6. Remove bolts securing front support to frame.7. Raise the front of the engine 1 in. (25.4 mm) and block under the engine.
Never support the engine by placing blocking under the oil pan. Damage to the oil pan or suction bell will result.
8. Remove engine front support. Remove timing gear cover retaining bolts. These bolts vary in length. Mark each bolt and its location for correct installation.9. Install two 1P7406 Lifting Eye Bolts in timing gear cover. Attach a hoist and pry timing gear cover off dowels in cylinder block. Remove the timing gear cover, the weight is approx. 85 lbs. (40 kg).
REMOVING TIMING GEAR COVER
2. Timing gear cover.Install Timing Gear Cover
1. Clean all gasket surfaces on timing gear cover and cylinder block. Clean water sleeve bores in cylinder heads and inspect and lubricate O-rings before installing.2. Install timing gear cover gasket. Install water sleeves in timing gear cover before installing cover. Replacement water sleeves are color coded to insure that new sleeves have the correct sized orifice to control coolant flow in the different engines. The 1140, 1145, and 1150 Series [4.1 in. (104.1 mm) and 4.5 in. (114.3 mm) stroke] use a silver code. The 1160 [5.0 in. (127.0 mm) stroke] uses a gold code.3. Install two 1P7406 Lifting Eye Bolts in timing gear cover. Attach hoist and position cover on engine. Make sure the oil pump gear teeth and the crankshaft gear teeth mesh.4. Install the timing gear cover retaining bolts.5. Connect oil cooler water outlet elbow to back side of timing gear cover.6. Trim the timing gear cover gasket flush with bottom face of cylinder block. Gaskets not cut square and flush with oil pan face will leak.7. Use an 8S6692 Water Sleeve Tool to slide water sleeves into cylinder heads and install clamps.8. Install front support. Remove blocking from beneath engine and lower engine into position. Install and tighten front support-to-frame mounting bolts.9. Lubricate the lip of the crankshaft front seal with clean engine oil (SAE 30). Install the crankshaft pulley.10. Install oil pump suction bell, oil pan gasket and oil pan. Tighten oil pan retaining bolts to 17 3 lb. ft. (2.4 0.4 mkg).11. Connect water temperature sending unit. Install tachometer drive housing and connect tachometer drive cable.12. Install the power steering pump, vacuum pump, alternator, radiator and all other components that were removed or disconnected.13. Fill the cooling system and lubricating system to the correct levels.