Information injection-pump assembly
ZEXEL
104740-9670
1047409670
Rating:
Cross reference number
ZEXEL
104740-9670
1047409670
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
1404 Test oil ISO4113orSAEJ967d
Test oil temperature
degC
45
45
50
Nozzle
105000-2010
Bosch type code
NP-DN12SD12TT
Nozzle holder
105780-2080
Opening pressure
MPa
14.7
14.7
15.19
Opening pressure
kgf/cm2
150
150
155
Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840
Inside diameter - outside diameter - length (mm) mm 2-6-840
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
Right R
Injection timing adjustment
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
52.3
51.8
52.8
Difference in delivery
mm3/st.
3
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2550
2550
2550
Average injection quantity
mm3/st.
10.9
7.4
14.4
Injection timing adjustment_03
Pump speed
r/min
2350
2350
2350
Average injection quantity
mm3/st.
33.8
31.3
36.3
Injection timing adjustment_04
Pump speed
r/min
2150
2150
2150
Average injection quantity
mm3/st.
44.5
42.4
46.6
Injection timing adjustment_05
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
52.3
51.3
53.3
Injection timing adjustment_06
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
51.4
49.4
53.4
Injection quantity adjustment
Pump speed
r/min
2350
2350
2350
Average injection quantity
mm3/st.
33.8
31.8
35.8
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
2700
2700
2700
Average injection quantity
mm3/st.
5
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
6.5
4.5
8.5
Difference in delivery
mm3/st.
2
Basic
*
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
6.5
4.5
8.5
Governor adjustment_03
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
2
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
62.5
45
80
Basic
*
Speed control lever angle
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF
Magnet OFF
0000000901
Pump speed
r/min
1100
1100
1100
Overflow quantity
cm3/min
390
258
522
Stop lever angle
Pump speed
r/min
1100
1100
1100
Pressure
kPa
431.5
402
461
Pressure
kgf/cm2
4.4
4.1
4.7
Basic
*
Stop lever angle_02
Pump speed
r/min
1100
1100
1100
Pressure
kPa
431.5
402
461
Pressure
kgf/cm2
4.4
4.1
4.7
Stop lever angle_03
Pump speed
r/min
1700
1700
1700
Pressure
kPa
578.5
549
608
Pressure
kgf/cm2
5.9
5.6
6.2
Stop lever angle_04
Pump speed
r/min
2550
2550
2550
Pressure
kPa
676.5
647
706
Pressure
kgf/cm2
6.9
6.6
7.2
0000001101
Pump speed
r/min
1100
1100
1100
Timer stroke
mm
2.5
2.3
2.7
Basic
*
_02
Pump speed
r/min
1100
1100
1100
Timer stroke
mm
2.5
2.2
2.8
_03
Pump speed
r/min
1700
1700
1700
Timer stroke
mm
4.6
4
5.2
_04
Pump speed
r/min
2550
2550
2550
Timer stroke
mm
7.3
6.8
7.8
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
5.8
5.7
5.9
MS dimension
mm
1
0.9
1.1
Control lever angle alpha
deg.
55.5
51.5
59.5
Control lever angle beta
deg.
36
31
41
Test data Ex:
0000001801 CONTROL LEVER ANGLE
Control lever angle measurement
1. Measure dimension Ya between the end of the lever and the flange face.
2. Measure the lever angle from the pin hole R (plate).
(A) = lever angle and lever reaction force measuring position
----------
Ya=8.4~12.2mm R=53mm
----------
Ya=8.4~12.2mm R=53mm Alpha=51.5~59.5deg Beta=31~41deg
----------
Ya=8.4~12.2mm R=53mm
----------
Ya=8.4~12.2mm R=53mm Alpha=51.5~59.5deg Beta=31~41deg
0000001901 POTENTIOMETER ADJUSTMENT
Injection quantity at pump speed N1 and lever position a
Voltage conversion formula: V+-0.03 = 0.077Q+2.63 (Applied voltage Vi)
----------
N1=750r/min a=9.1+-0.5deg Vi=10V
----------
----------
N1=750r/min a=9.1+-0.5deg Vi=10V
----------
Information:
Introduction
Procedure to prevent injector Plunger Spring failure due to inadequate fuel system priming.
The low-pressure fuel system must be primed after injector replacement or other repair to the low-pressure fuel system circuit which may allow air to enter the system.
Inadequate priming can result in air being present in the low-pressure fuel system and inside the injectors.
Attempting to start the engine without adequate priming may result in an early hour failure of the injector plunger spring.
Follow the procedure below to prevent injector failure due to inadequate priming.
DO NOT START THE ENGINE WITHOUT PRIMING THE FUEL SYSTEM
Illustration 1 g03735591
Damaged plunger spring due to improper fuel system primingFuel System Priming Procedure:
Disconnect the injector harness at the valve cover.
Use the hand primer to fill the fuel system. Pump until the hand primer becomes too hard to depress by hand.
Crank the engine 3 times for 15 seconds each. Reapply the hand primer after each cranking cycle.
Once the hand primer remains hard to depress after the 15 second crank, reconnect the injector harness and start the engine.
Clear any related fault codes (ET) that were logged while cranking the engine with the injector harness disconnected.
Illustration 2 g03736011
Procedure to prevent injector Plunger Spring failure due to inadequate fuel system priming.
The low-pressure fuel system must be primed after injector replacement or other repair to the low-pressure fuel system circuit which may allow air to enter the system.
Inadequate priming can result in air being present in the low-pressure fuel system and inside the injectors.
Attempting to start the engine without adequate priming may result in an early hour failure of the injector plunger spring.
Follow the procedure below to prevent injector failure due to inadequate priming.
DO NOT START THE ENGINE WITHOUT PRIMING THE FUEL SYSTEM
Illustration 1 g03735591
Damaged plunger spring due to improper fuel system primingFuel System Priming Procedure:
Disconnect the injector harness at the valve cover.
Use the hand primer to fill the fuel system. Pump until the hand primer becomes too hard to depress by hand.
Crank the engine 3 times for 15 seconds each. Reapply the hand primer after each cranking cycle.
Once the hand primer remains hard to depress after the 15 second crank, reconnect the injector harness and start the engine.
Clear any related fault codes (ET) that were logged while cranking the engine with the injector harness disconnected.
Illustration 2 g03736011