Information injection-pump assembly
ZEXEL
104740-2510
1047402510
Rating:
Cross reference number
ZEXEL
104740-2510
1047402510
Zexel num
Bosch num
Firm num
Name
104740-2510
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)
With S/T O-ring; S/T OFF. OFF
With S/T O-ring; S/T OFF. OFF
Injection timing adjustment
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
35.3
34.9
35.7
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
30.1
24.6
35.6
Oil temperature
degC
48
46
50
Injection timing adjustment_03
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
29.8
27.3
32.3
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
31.2
28.2
34.2
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
35.3
34.3
36.3
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_06
Pump speed
r/min
1800
1800
1800
Average injection quantity
mm3/st.
32.6
30.1
35.1
Oil temperature
degC
50
48
52
Injection timing adjustment_07
Pump speed
r/min
2400
2400
2400
Average injection quantity
mm3/st.
33.6
30.1
37.1
Oil temperature
degC
52
50
54
Injection quantity adjustment
Pump speed
r/min
2700
2700
2700
Average injection quantity
mm3/st.
14
12
16
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
10.5
17.5
Difference in delivery
mm3/st.
5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2800
2800
2800
Average injection quantity
mm3/st.
5
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
10.5
9.5
11.5
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.
10.5
8.5
12.5
Difference in delivery
mm3/st.
2.5
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_03
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
5
Oil temperature
degC
48
46
50
Boost compensator adjustment
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
20.5
14
27
Oil temperature
degC
50
48
52
Lever angle (shim thickness)
mm
5.6
5.55
5.65
Remarks
From idle
From idle
Boost compensator adjustment_02
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
15.2
8.2
22.2
Oil temperature
degC
50
48
52
Lever angle (shim thickness)
mm
5.6
5.55
5.65
Remarks
From idle
From idle
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60
50
70
Basic
*
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60
50
70
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
422
393
451
Pressure with S/T ON
kgf/cm2
4.3
4
4.6
Pressure with S/T OFF
kPa
324
275
373
Pressure with S/T OFF
kgf/cm2
3.3
2.8
3.8
Basic
*
Oil temperature
degC
50
48
52
Remarks
ON
ON
Stop lever angle_02
Pump speed
r/min
1000
1000
1000
Pressure with S/T ON
kPa
421.5
382
461
Pressure with S/T ON
kgf/cm2
4.3
3.9
4.7
Pressure with S/T OFF
kPa
323.5
265
382
Pressure with S/T OFF
kgf/cm2
3.3
2.7
3.9
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_03
Pump speed
r/min
1800
1800
1800
Pressure with S/T ON
kPa
588.5
549
628
Pressure with S/T ON
kgf/cm2
6
5.6
6.4
Oil temperature
degC
50
48
52
Stop lever angle_04
Pump speed
r/min
2400
2400
2400
Pressure with S/T ON
kPa
725.5
686
765
Pressure with S/T ON
kgf/cm2
7.4
7
7.8
Oil temperature
degC
52
50
54
0000001101
Pump speed
r/min
1000
1000
1000
Timer stroke with S/T ON
mm
3.1
2.7
3.5
Timer stroke with S/T OFF
mm
1.9
1.7
2.1
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_02
Pump speed
r/min
1000
1000
1000
Timer stroke with S/T ON
mm
3.1
2.6
3.6
Timer stroke with S/T OFF
mm
1.9
1.6
2.2
Basic
*
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1800
1800
1800
Timer stroke with S/T OFF
mm
5.6
5.1
6.1
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
2400
2400
2400
Timer stroke with S/T OFF
mm
7.35
6.9
7.8
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
0.8
0.7
0.9
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 = 0.06740Q+3.4462
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=8.7(deg) L=5.6+-0.05(mm) Vi=10(V)
----------
V1=(2.34+-0.75(V)) V2=9.96++(V) K=Vi=10(V)
----------
N=700(r/min) a=8.7(deg) L=5.6+-0.05(mm) Vi=10(V)
----------
V1=(2.34+-0.75(V)) V2=9.96++(V) K=Vi=10(V)
0000001901 W-CSD ADJUSTMENT
Adjustment of the W-CSD
1. Adjustment of the advance angle of the timer
(1)Determine the timer advance angle from the figure (Q)'s graph.
(2)(1) Adjust using the screw (I) so that the timer advance angle determined in item (1) is obtained.
2. Intermediate lever position setting [refer to fig (O), (P)]
(1)Insert a block gauge L1 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). Hold control lever (G) against screw (F) then fix the nut.
3. W-CSD lever adjustment [refer to fig (O) and fig (P)]
(1)Insert a block gauge thickness L3 determined from the graph Q (L-theta) between the idling set screw (H) and the control lever (G).
(2)Adjust the screw (B) until the screw (F) contacts the control lever (G). Then fix locknut (A).
Note
The temperature of the wax at adjustment must not exceed a.
X:Temperature theta (deg C)
Y1:Timer stroke TA (mm)
Y2:Control lever L dimension (mm; control lever position)
Graph TA-theta
theta (deg C) <= 10: TA = 0.82
10 <= theta (deg C) <= 20: TA = -0.027 theta + 1.09
20 <= theta (deg C) <= 40: TA = -0.0275 theta + 1.1
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+-0.05(mm) L2=5.3(mm) L3=L+-0.5(mm) a=30(degC)
----------
L1=3.0+-0.05(mm) L2=5.3(mm)
----------
L1=3.0+-0.05(mm) L2=5.3(mm) L3=L+-0.5(mm) a=30(degC)
----------
L1=3.0+-0.05(mm) L2=5.3(mm)
Information:
Start By:a. remove timing gear coverb. remove flywheel housingc. remove pistons and connecting rod assembliesd. remove crankshaft rear seal and wear sleevee. remove crankshaft front seal and wear sleeve Check the bearing caps for a number as to their location. If a number can not be seen, put a number on the left side of cylinder block and bearing cap. 1. Remove bolts (1) that hold main bearing caps (2) to the block, and remove main bearing caps (2). 2. Install one of the bolts from the front pulley in each end of the crankshaft.3. Fasten a hoist to crankshaft (3), and remove crankshaft (3) from the block. The weight is 159 kg (350 lb.). If new main bearings are not to be installed, keep old bearings with identification as to their location in cylinder block. 4. Use tooling (A) to remove the crankshaft gear.5. Use tooling (B) if necessary to remove the dowel and the pin.Install Crankshaft
If the crankshaft journals and bores for the block and rods were measured at disassembly and found to be within specifications, no further checks are necessary. However, if the serviceman still wants to measure the bearing clearances, Plastigage is recommended. Lead wire, shim stock or use of a dial bore gauge can damage the bearing surface.The serviceman must be very careful to use Plastigage, tool (B) correctly. The following points must be remembered:... Make sure that the backs of the bearings and the bores are clean and dry.... Make sure that the bearing locking tabs are properly seated in their slots.... The crankshaft must be free of oil where the Plastigage touches it.... If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings.... Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing.... Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.... Do not turn the crankshaft with the Plastigage installed.... Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements.... Remove the Plastigage before reinstalling the cap.When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004 in.) the readings may be low by 0.013 to 0.025 mm (.0005 to .0010
If the crankshaft journals and bores for the block and rods were measured at disassembly and found to be within specifications, no further checks are necessary. However, if the serviceman still wants to measure the bearing clearances, Plastigage is recommended. Lead wire, shim stock or use of a dial bore gauge can damage the bearing surface.The serviceman must be very careful to use Plastigage, tool (B) correctly. The following points must be remembered:... Make sure that the backs of the bearings and the bores are clean and dry.... Make sure that the bearing locking tabs are properly seated in their slots.... The crankshaft must be free of oil where the Plastigage touches it.... If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings.... Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing.... Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.... Do not turn the crankshaft with the Plastigage installed.... Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements.... Remove the Plastigage before reinstalling the cap.When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004 in.) the readings may be low by 0.013 to 0.025 mm (.0005 to .0010
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104740-2510
INJECTION-PUMP ASSEMBLY