104745-9340 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047459340

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104745-9340 1047459340

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Cross reference number

ZEXEL 104745-9340 1047459340

Zexel num

Bosch num

Firm num

Name

104745-9340

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. 41.3 38.8 43.8

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 49.9 48.9 50.9

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. 46.3 43.8 48.8

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. 39.7 39.7 39.7

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

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

A:Potentiometer standards B:ON, OFF switch standard G:ON-->OFF D:OFF-->ON E:Adjusting point F:Checking point P:Boost pressure Vi:Applied voltage C1:Full-speed C2:Idle Q:Injection quantity N:Pump speed V:Output voltage C:Control lever angle
----------

----------
V1=1.6+-0.03V V2=7.6+-1.1V C3=(4.9+-2.5)deg C4=(19.4+-4)deg Vi=10V P1=-kPa P2=-mmHg

Information:

MAIN BEARINGS
1. Bolt (partially hidden under oil pump). 2. Front cover. 3. Oil pump. 4. Bolts (two per cap). 5. Main bearing cap.
ADAPTER
6. 8S5131 Adpater.4. Use a commercially available bearing removal tool to roll out upper halves of main bearings.Install Main Bearings
1. Use a commercially available bearing removal tool to install the upper halves of the main bearings. Lubricate with clean engine oil (SAE 30) before installing. The main bearing half with the oil hole is the upper half. Be sure to install correctly.2. Lubricate lower halves of main bearings with engine oil (SAE 30). Install main bearing caps (5) so number on cap corresponds with number on saddle of cylinder block. Both numbers must be on same side of block.3. Put engine oil on the threads of the bolts and the face of the washers and install bolts (4) into the cylinder block.4. Use adapter (6) to install bolt (1) when front cover (2) and oil pump (3) are mounted on cylinder block. For 1140 (36B1-36B1923), 1145 (97B1-97B6154), 1150 (96B1-96B6580), 1160 (95B1-95B13691) Engines, install bolt (1) using a 9S7353 Torque Wrench with an 8S5131 Adapter. Do not tighten bolt (1) at this time. Tighten bolt (1) in the number sequence shown with the other bolts but tighten it to a first torque of 48 lb. ft. (6.6 mkg) and a last torque of 140 lb. ft. (19.4 mkg). See Step 5 for torque of the other bolts.For 1140 (36B1924-Up), 1145 (97B6155-Up), 1150 (96B6581-Up), 1160 (95B13692-Up) Engines, install bolt (1) using a 9S7353 Torque Wrench with an 8S5131 Adapter. Do not tighten bolt (1) at this time. Tighten bolt (1) in the number sequence shown with the other bolts but tighten it to a first torque of 24 lb. ft. (3.3 mkg). Put a mark on the bolt and cap. Tighten the bolt an added 120° 5° from the mark. See Step 6 for torque of the other bolts.
MAIN BEARINGS
1. Bolt (partially hidden under oil pump). 2. Front cover. 3. Oil pump. 4. Bolts (two per cap). 5. Main bearing cap.
ADAPTER
6. 8S5131 Adapter.5. Tighten the bolts for the main bearing caps in the number sequence shown to a first torque of 60 15 lb. ft. (8.3 2.1 mkg). Tighten all bolts in the number sequence shown (hand torque only) to a last torque of 175 10 lb. ft. (24.2 1.4 mkg).
BOLT TIGHTENING SEQUENCE6. Tighten the bolts for the main bearing caps in the number sequence shown to a first torque of 30 3 lb. ft. (4.1 0.4 mkg). Put a mark on each bolt and cap and tighten, in the number sequence shown, an added 120° 5° from the mark.