104761-4281 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047614281

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104761-4281 1047614281

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Cross reference number

ZEXEL 104761-4281 1047614281

Zexel num

Bosch num

Firm num

Name

104761-4281

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 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 51 50.5 51.5

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 700 700 700

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Average injection quantity mm3/st. 57.4 56.9 57.9

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 60 59.5 60.5

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 51 50 52

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 700 700 700

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Average injection quantity mm3/st. 57.4 56.4 58.4

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 60 59 61

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 61.6 57.6 65.6

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 1800 1800 1800

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 57.6 53.6 61.6

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 25.9 23.9 27.9

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2500 2500 2500

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2300 2300 2300

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 25.9 23.4 28.4

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 8.7 6.7 10.7

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 8.7 6.2 11.2

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

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. 61.5 51.5 81.5

Basic *

Oil temperature degC 48 46 50

Remarks
Full

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. 61.5 51.5 81.5

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 350 350 350

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

Speed control lever angle_02

Pump speed r/min 250 250 250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5

Oil temperature degC 48 46 50

Remarks
Magnet OFF at full-load position

0000000901

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Overflow quantity with S/T ON cm3/min 440 310 570

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 53.3 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T ON kPa 549 510 588

Pressure with S/T ON kgf/cm2 5.6 5.2 6

Pressure with S/T OFF kPa 441 412 470

Pressure with S/T OFF kgf/cm2 4.5 4.2 4.8

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 53.3 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T OFF kPa 441 402 480

Pressure with S/T OFF kgf/cm2 4.5 4.1 4.9

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_03

Pump speed r/min 1700 1700 1700

Boost pressure kPa 53.3 53.3 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T OFF kPa 588 549 627

Pressure with S/T OFF kgf/cm2 6 5.6 6.4

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T ON mm 4.6 4.2 5

Timer stroke with S/T OFF mm 3.1 2.9 3.3

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T OFF mm 2 1.5 2.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T ON mm 4.6 4.1 5.1

Timer stroke with S/T OFF mm 3.1 2.8 3.4

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T OFF mm 5.3 4.8 5.8

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T ON mm 7 6.5 7.4

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 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 47 46.5 47.5

Timer stroke TA mm 2.4 2.2 2.6

Timer stroke variation dT mm 0.7 0.7 0.7

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 47 46 48

Timer stroke TA mm 2.4 2.2 2.6

Timer stroke variation dT mm 0.7 0.7 0.7

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 33 30.5 35.5

Timer stroke TA mm 1.6 1.1 2.1

Timer stroke variation dT mm 1.5 1.5 1.5

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 6.76 6.66 6.86

MS dimension mm 1.3 1.2 1.4

BCS stroke mm 2.8 2.6 3

Pre-stroke mm 0.1 0.08 0.12

Control lever angle alpha deg. 55.5 51.5 59.5

Control lever angle beta deg. 43 38 48

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Potentiometer adjustment 1. Applied voltage: Vi 2. Boost pressure = P1kPa {P2 mmHg} 3. Set the control lever at the adjusting point. Position the dummy bolt against the lever and fix. 4. Assemble the potentiometer to obtain output voltage V1 (V) at the fixed position. 5. After mounting the potentiometer, remove the dummy bolt. The switch voltage specification is the value when the idle lever position is V6. N:Pump speed Q:Injection quantity V:Output voltage A:Performance standards B:ON, OFF switch standard C:Angle of the control lever D:OFF-->ON E:OFF-->ON F:Adjusting point G:Checking point C1:Idle C2:Full-speed
----------
V1=3.08+-0.03V V6=0V P1=0kPa P2=0mmHg Vi=10.0V
----------
N1=700r/min Q1=22.9+-1.0cm3/1,000st V1=3.08+-0.03V V2=1.1+-0.6V V3=Above7.7V V4=1.3+-0.8V V5=3.7+-0.8V C3=7.9deg+-5deg C4=22.4deg+-5deg

Information:

1W4563, 1W5634 Gear Group
(1) Fuel pump drive gear.(2) Washer. Assemble with large diameter away from gear.(3) Bolt. With the timing pin and timing bolt correctly installed, put a clockwise force of 70 N m (50 lb ft) on the drive gear for the fuel pump and tighten bolt to ... 270 25 N m (200 20 lb ft)(4) Fuel pump idler gear. End play for the idler gear (new) ... 0.10 to 0.41 mm (.004 to .016 in)Maximum permissible end play (worn) ... 0.86 mm (.034 in)Bore in bearing for the idler gear (new) ... 35.004 0.048 mm (1.3781 .0019 in)Diameter of shaft for idler gear (new) ... 34.902 0.020 mm (1.3741 .0008 in)Clearance between shaft and bearing (new) ... 0.033 to 0.168 mm (.0013 to .0066 in)Maximum permissible clearance between shaft and bearing (worn) ... 0.23 mm (.009 in)(5) Plate. Assemble machined side of plate adjacent to the shaft.(6) Bolt. Tighten to ... 25 7 N m (18 5 lb ft)(7) Camshaft gear.(8) Bolts. Tighten to ... 55 7 N m (40 7 lb ft)(9) Crankshaft gear. Maximum temperature of the gear for installation on the crankshaft ... 316°C (600°F)(10) Idler gear for oil pump.(11) Drive gear for oil pump.2P9642 Gear Group
(1) Fuel pump drive gear.(2) Washer. Assemble with large diameter away from gear.(3) Bolt. With the timing pin and timing bolt correctly installed, put a clockwise force of 70 N m (50 lb ft) on the drive gear for the fuel pump and tighten bolt to ... 149 7 N m (110 5 lb ft)(4) Fuel pump idler gear. End play for the idler gear (new) ... 0.10 to 0.41 mm (.004 to .016 in)Maximum permissible end play (worn) ... 0.86 mm (.034 in)Bore in bearing for the idler gear (new) ... 35.004 0.048 mm (1.3781 .0019 in)Diameter of shaft for idler gear (new) ... 34.902 0.020 mm (1.3741 .0008 in)Clearance between shaft and bearing (new) ... 0.033 to 0.168 mm (.0013 to .0066 in)Maximum permissible clearance between shaft and bearing (worn) ... 0.23 mm (.009 in)(5) Plate. Assemble machined side of plate adjacent to the shaft.(6) Bolt. Tighten to ... 25 7 N m (18 5 lb ft)(7) Camshaft gear.(8) Bolts. Tighten to ... 55 7 N m (40 7 lb ft)(9) Crankshaft gear. Maximum temperature of the gear for installation on the crankshaft ... 316°C (600°F)(10) Idler gear for oil pump.(11) Drive gear for oil pump.