Information injection-pump assembly
ZEXEL
104740-2176
1047402176
Rating:
Cross reference number
ZEXEL
104740-2176
1047402176
Zexel num
Bosch num
Firm num
Name
104740-2176
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
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
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)
Left L
Left L
(Solenoid timer adjustment condition)
ON
Injection timing adjustment
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
31
30.6
31.4
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
29.4
27.4
31.4
Oil temperature
degC
50
48
52
Injection timing adjustment_03
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
28.3
26.3
30.3
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
31
30
32
Difference in delivery
mm3/st.
2.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
1800
1800
1800
Average injection quantity
mm3/st.
29.8
27.8
31.8
Oil temperature
degC
50
48
52
Injection timing adjustment_06
Pump speed
r/min
2400
2400
2400
Average injection quantity
mm3/st.
29.8
27.8
31.8
Oil temperature
degC
52
50
54
Injection quantity adjustment
Pump speed
r/min
2700
2700
2700
Average injection quantity
mm3/st.
14.8
12.8
16.8
Difference in delivery
mm3/st.
4.5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_02
Pump speed
r/min
2700
2700
2700
Average injection quantity
mm3/st.
14.8
11.3
18.3
Difference in delivery
mm3/st.
5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2900
2900
2900
Average injection quantity
mm3/st.
6
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
9.6
8.6
10.6
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
9.6
7.6
11.6
Difference in delivery
mm3/st.
2.5
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_03
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
3
Oil temperature
degC
50
48
52
Boost compensator adjustment
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
13.5
7
20
Oil temperature
degC
50
48
52
Lever angle (shim thickness)
mm
5.7
5.7
5.7
Remarks
From idle
From idle
Boost compensator adjustment_02
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
9.6
2.6
16.6
Oil temperature
degC
50
48
52
Lever angle (shim thickness)
mm
5.7
5.7
5.7
Remarks
From idle
From idle
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
55
75
Basic
*
Oil temperature
degC
48
46
50
Timer adjustment_02
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
55
75
Oil temperature
degC
48
46
50
Speed control lever angle
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
0000000901
Pump speed
r/min
1000
1000
1000
Overflow quantity with S/T ON
cm3/min
440
310
570
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
1000
1000
1000
Pressure with S/T ON
kPa
412
383
441
Pressure with S/T ON
kgf/cm2
4.2
3.9
4.5
Pressure with S/T OFF
kPa
353
304
402
Pressure with S/T OFF
kgf/cm2
3.6
3.1
4.1
Basic
*
Oil temperature
degC
50
48
52
Remarks
ON
ON
Stop lever angle_02
Pump speed
r/min
1000
1000
1000
Pressure
kPa
412.5
375
450
Pressure
kgf/cm2
4.2
3.8
4.6
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_03
Pump speed
r/min
1400
1400
1400
Pressure
kPa
510
470
550
Pressure
kgf/cm2
5.2
4.8
5.6
Oil temperature
degC
50
48
52
Stop lever angle_04
Pump speed
r/min
2400
2400
2400
Pressure
kPa
735
695
775
Pressure
kgf/cm2
7.5
7.1
7.9
Oil temperature
degC
52
50
54
0000001101
Pump speed
r/min
1000
1000
1000
Timer stroke with S/T ON
mm
4.4
4.2
4.6
Timer stroke with S/T OFF
mm
3.2
2.8
3.6
Basic
*
Oil temperature
degC
50
48
52
Remarks
ON
ON
_02
Pump speed
r/min
1000
1000
1000
Timer stroke with S/T ON
mm
4.4
4.1
4.7
Timer stroke with S/T OFF
mm
3.2
2.7
3.7
Basic
*
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1400
1400
1400
Timer stroke with S/T ON
mm
6.4
5.9
6.9
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
2400
2400
2400
Timer stroke with S/T ON
mm
10.65
10.2
11.1
Oil temperature
degC
52
50
54
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
6.78
6.68
6.88
MS dimension
mm
0.9
0.8
1
Control lever angle alpha
deg.
25
23
27
Control lever angle beta
deg.
42
37
47
Test data Ex:
0000001801 POTENTIOMETER ADJUSTMENT
Adjustment of the potentiometer
At pump speed N and with the control lever angle at a from the idle position (clearance L), convert the injection quantity obtained to a voltage value using the graph and adjust the potentiometer.
Vo:Output voltage
Q:Injection quantity
A:Performance standards
C:Position of the control lever
G:Idle
H:Full speed
E:J = formula V+-0.03 = 0.0656Q+3.1852 14.4 <= Q <= 19.5 (mm3/st)
V+-0.03 = 0.1020Q + 2.6597 11.1<= Q <= 14.4 mm3/st)
V+-0.03 = 0.1103Q + 2.5678 7.5 <= Q <= 11.1 (mm3/st)
K = Vi: applied voltage
X:Injection quantity (mm3/st)
Y:Voltage (V)
M:Connecting diagram for the potentiometer
O:Output
P:Output when (2) and (3) connected.
----------
N=700(r/min) a=9(deg) L=5.7(mm) Vi=10(V)
----------
V1=1.47+-0.5(V) V2=(10.0(V))
----------
N=700(r/min) a=9(deg) L=5.7(mm) Vi=10(V)
----------
V1=1.47+-0.5(V) V2=(10.0(V))
0000001901 W-CSD ADJUSTMENT
Adjustment of the W-CSD
Set the intermediate lever [Refer to (O), (P)]
(1)Insert a block gauge L1+-0.05 mm between the idling set screw (H) and the control lever (G).
2. Insert a shim thickness L2+-0.05 (mm) between the intermediate lever D and the intermediate lever bracket E. Position screw F against the control lever G and tighten the nut.
W-CSD lever adjustment (refer to (O), (P))
(1)After completing (1) above, remove the block gauge L1 and the shim with the thickness L2.
(2)Insert a block gauge thickness L3 determined from the graph (Q) between the idling set screw (H) and the control lever (G).
(3)Adjust the screw (B) until the screw (F) contacts the control lever (G). Then fix locknut (A).
(4)The temperature of the wax at adjustment must not exceed a.
X:Temperature theta (deg C)
Y:Control lever L dimension (mm; control lever position)
Q:L-theta graph
theta (deg C) <= 10: L = 3.9
10 <= theta (deg C) <= 30 L = -0.09 theta + 4.8
30 <= theta (deg C) <= 54.3 L = -0.086 theta + 4.68
----------
L1=3.0(mm) L2=5.3(mm) L3=L1+-0.05(mm) a=30(degC)
----------
L1=3.0(mm) L2=5.3(mm)
----------
L1=3.0(mm) L2=5.3(mm) L3=L1+-0.05(mm) a=30(degC)
----------
L1=3.0(mm) L2=5.3(mm)
Information:
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Loosen hose clamps and slide hose (1) down on the tube assembly. 2. Remove tube assembly (4).3. Disconnect hose assembly (3), loosen two clamps and slide hose (2) on tube assembly. 4. Remove bolts (5). 5. Remove the supply tube (6) and drain tube (7) and the gaskets. 6. Disconnect tube assembly (8) from the aftercooler housing and remove bolts (9).7. Attach a hoist to the cylinder head lift brackets. 8. Remove head bolts (10) and the cylinder head from the engine block. The weight of the cylinder head assembly is 177 kg (390 lb).
Do not set the cylinder head on a flat surface because of possible damage to the fuel injection nozzle tips.
Install Cylinder Head
When the cylinder head is removed, a new spacer plate gasket must be installed. See the topic, Remove And Install Spacer Plate, in this manual. 1. Clean the surfaces of the cylinder head and the cylinder block that make contact with each other. Make sure the surfaces are clean and dry. Install a new dry gasket (2) on the cylinder block.2. Fasten a hoist to the cylinder head (1) and put it on position on the cylinder block.3. Put 2P2506 Thread Lubricant on all the head bolts and rocker shaft bolts except bolt (25). Install the head bolts and washers that hold the head in place. Do not tighten bolts at this time.4. Loosen the adjusting screws on the rocker arms for valve clearance. This will prevent a bent valve or push rod at installation. 5. Install push rods (4) and rocker shaft assembly (3). Install the bolts and washers that hold the rocker shaft in place. 6. Tighten the bolts as follows:a. Tighten bolts 1 through 26 in number sequence to a torque of 155 N m (115 lb ft).b. Tighten bolts 1 through 26 again in number sequence to a torque of 250 17 N m (185 13 lb ft).c. Tighten bolts 1 through 26 again in number sequence (hand tighten only) to a torque of 250 17 N m (185 13 lb ft).d. Tighten bolts A through G in letter sequence (hand tighten only) to a torque of 43 7 N m (32 5 lb ft). 6. Make an adjustment until the intake valve clearance is 0.38 mm (.015 in) and the exhaust valve clearance is 0.64 mm (.025 in). Tighten the locknuts (5) for the adjusting screws to a torque of 29 7 N m (21 5 lb ft).7. Connect tube assembly (6) and install the bolts to fasten clips (7). 8. Inspect the turbocharger cartridge gaskets and make replacements if necessary. Install gaskets and the turbocharger supply tube assembly (8) and drain tube assembly (9). 9. Make sure the gasket for the water pump bypass elbow is in good condition and install two bolts (11) to fasten elbow (12) to cylinder
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104740-2176
INJECTION-PUMP ASSEMBLY