104761-4380 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047614380

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104761-4380 1047614380

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Cross reference number

ZEXEL 104761-4380 1047614380

Zexel num

Bosch num

Firm num

Name

104761-4380

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

Checker parts number 407980-228*

ECU part number 407913-1342

Wire harness 407980-2300

Intermediate harness 157992-8900

Injection timing adjustment

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 50.2 49.7 50.7

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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 56.4 55.9 56.9

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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 62 61.5 62.5

Difference in delivery mm3/st. 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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 50.2 49.2 51.2

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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 56.4 55.4 57.4

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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 62 61 63

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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 58.7 57.7 59.7

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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 56.7 52.7 60.7

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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 22.8 20.8 24.8

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

TCV duty (%) F TCV 60Hz % 100 100 100

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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 22.8 20.3 25.3

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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 6.6 4.6 8.6

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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 6.6 4.1 9.1

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 650 650 650

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 3

Oil temperature degC 50 48 52

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 0 0 0

Average injection quantity mm3/st. 66.5 51.5 81.5

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF

Speed control lever angle_02

Pump speed r/min 150 150 150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 0 0 0

Average injection quantity mm3/st. 5

Oil temperature degC 48 46 50

Remarks
Magnet OFF

0000000901

Pump speed r/min 1100 1100 1100

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

TCV duty (%) F TCV 60Hz % 100 100 100

Overflow quantity cm3/min 600 468 732

Basic 50+-2

Stop lever angle

Pump speed r/min 1100 1100 1100

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

TCV duty (%) F TCV 60Hz % 100 100 100

Pressure kPa 579 550 608

Pressure kgf/cm2 5.9 5.6 6.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 100 100 100

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

TCV duty (%) F TCV 60Hz % 100 100 100

Pressure kPa 294 294

Pressure kgf/cm2 3 3

Oil temperature degC 48 46 50

Stop lever angle_03

Pump speed r/min 1100 1100 1100

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

TCV duty (%) F TCV 60Hz % 100 100 100

Pressure kPa 579 540 618

Pressure kgf/cm2 5.9 5.5 6.3

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1800 1800 1800

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

TCV duty (%) F TCV 60Hz % 100 100 100

Pressure kPa 667 618 716

Pressure kgf/cm2 6.8 6.3 7.3

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1100 1100 1100

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

TCV duty (%) F TCV 60Hz % 70 70 70

Timer stroke mm 3.5 3.2 3.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 500 500 500

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

TCV duty (%) F TCV 60Hz % 100 100 100

Timer stroke mm 5.6 3.6 7.6

Oil temperature degC 48 46 50

_03

Pump speed r/min 1100 1100 1100

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

TCV duty (%) F TCV 60Hz % 100 100 100

Timer stroke mm 7 5 9

Oil temperature degC 50 48 52

_04

Pump speed r/min 1100 1100 1100

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

TCV duty (%) F TCV 60Hz % 70 70 70

Timer stroke mm 3.5 3.1 3.9

Oil temperature degC 50 48 52

_05

Pump speed r/min 1100 1100 1100

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

TCV duty (%) F TCV 60Hz % 0 0 0

Timer stroke mm 0 0 0

Oil temperature degC 50 48 52

_06

Pump speed r/min 1800 1800 1800

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

TCV duty (%) F TCV 60Hz % 100 100 100

Timer stroke mm 6.95 6.5 7.4

Oil temperature degC 50 48 52

0000001301

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000002701

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 2.9 2.7 3.1

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:

0000001901 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. At TCV duty 100% A:Adjusting point B:Performance standards C:Control lever angle N:Pump speed V:Output voltage Q:Injection quantity C1:Idle C2:Full speed
----------
V1=6.00+-0.03V P1=0kPa P2=0mmHg Vi=10V
----------
N1=1240r/min Q1=40.6+-1.0cm3/1,000st V1=6.00+-0.03V V2=1.04+-0.69V V3=8.18+-0.61V a=-deg

Information:

(1) Thickness of spacer plate ... 9.970 0.025 mm (.3925 .0010 in) Thickness of spacer plate gasket ... 0.208 0.025 mm (.0082 .0010 in) For height of liner over top of spacer plate make reference to Cylinder Liner Projection.(2) Camshaft bearing bore (installed) ... 58.80 0.06 mm (2.315 .002 in) Bore in block for camshaft bearings ... 65.100 0.025 mm (2.5630 .0010 in)(3) Bore in block for main bearings (standard size) ... 96.926 0.013 mm (3.8160 .0005 in) Bore in block for main bearings 0.51 mm (.020 in) oversize ... 97.436 0.013 mm (3.8361 .0005 in)(4) Dimension from center of main bearing bore to top of cylinder block (new) ... 383.515 0.165 mm (15.099 .0064 in)(5) Dimension from center of main bearing bore to bottom of cylinder block (new) ... 153.99 0.10 mm (6.063 .004 in)(6) Torque for bolts holding bearing caps for main bearings: a. Put 2P2506 Thread Lubricant on threads and washer face.b. Tighten all bolts to ... 41 4 N m (30 3 lb ft)c. Put a mark on each bolt and cap.d. Tighten all bolts from mark ... 90 5° Install bearing caps with the part number toward the front of the engine. Be sure that the mark (number) on the bearing cap next to the bolt hole is in agreement with the mark in the cylinder block.(7) Clearance between main bearing cap and cylinder block ... 0.033 mm (.0013 in) tight to 0.043 mm (.0017 in) loose Main bearing cap width ... 165.095 0.020 mm (6.4998 .0008 in)Width of cylinder block for main bearing cap ... 165.100 0.018 mm (6.5000 .0007 in) (8) Piston cooling orifice.
There are holes in the bores for the main bearings, between the cylinders for piston cooling orifices. These holes must have orifices (8) installed.
(9) Distance two dowels extend from the surface of the cylinder block ... 19.8 0.5 mm (.78 .02 in)(10) Distance hollow dowel extends from the surface of the cylinder block ... 16.0 0.5 mm (.63 .02 in)(11) Depth to install two dowels below the surface of the cylinder block (apply loctite #11358) ... 1.0 0.5 mm (.04 .02 in)(12) Distance dowels extend from the front face of the cylinder block ... 22.4 0.5 mm (.88 .02 in)(13) Distance stud extends from the front face of the cylinder block ... 15.7 0.5 mm (.62 .02 in)(14) Distance two dowels extend from the rear face of the cylinder block ... 12.7 0.5 mm (.50 .02 in)