Information injection-pump assembly
ZEXEL
104741-5420
1047415420
Rating:
Cross reference number
ZEXEL
104741-5420
1047415420
Zexel num
Bosch num
Firm num
Name
104741-5420
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
Injection timing adjustment
Pump speed
r/min
1075
1075
1075
Average injection quantity
mm3/st.
45.3
44.8
45.8
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
36.1
36.1
36.1
Oil temperature
degC
48
46
50
Injection timing adjustment_03
Pump speed
r/min
1075
1075
1075
Average injection quantity
mm3/st.
45.3
44.3
46.3
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
51.6
51.6
51.6
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
1800
1800
1800
Average injection quantity
mm3/st.
55.4
55.4
55.4
Oil temperature
degC
50
48
52
Injection quantity adjustment
Pump speed
r/min
2300
2300
2300
Average injection quantity
mm3/st.
18
15
21
Difference in delivery
mm3/st.
5.5
Basic
*
Oil temperature
degC
52
50
54
Injection quantity adjustment_02
Pump speed
r/min
2500
2500
2500
Average injection quantity
mm3/st.
6
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2300
2300
2300
Average injection quantity
mm3/st.
18
15
21
Difference in delivery
mm3/st.
5.5
Oil temperature
degC
52
50
54
Governor adjustment
Pump speed
r/min
385
385
385
Average injection quantity
mm3/st.
7.5
5.5
9.5
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
385
385
385
Average injection quantity
mm3/st.
7.5
5.5
9.5
Difference in delivery
mm3/st.
2
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60
60
100
Basic
*
Oil temperature
degC
48
46
50
Remarks
IDLE
IDLE
Timer adjustment_02
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
80
60
100
Oil temperature
degC
48
46
50
Speed control lever angle
Pump speed
r/min
385
385
385
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
1300
1300
1300
Oil temperature
degC
50
48
52
Remarks
MEASURE
MEASURE
Stop lever angle
Pump speed
r/min
1300
1300
1300
Pressure with S/T OFF
kPa
441
421
461
Pressure with S/T OFF
kgf/cm2
4.5
4.3
4.7
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_02
Pump speed
r/min
1300
1300
1300
Pressure with S/T OFF
kPa
441
421
461
Pressure with S/T OFF
kgf/cm2
4.5
4.3
4.7
Basic
*
Oil temperature
degC
50
48
52
0000001101
Pump speed
r/min
1300
1300
1300
Timer stroke with S/T OFF
mm
4.2
4
4.4
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
550
550
550
Timer stroke with S/T ON
mm
0.5
0.5
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
850
850
850
Timer stroke with S/T OFF
mm
0.5
0.1
1.3
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
1300
1300
1300
Timer stroke with S/T OFF
mm
4.2
4
4.4
Basic
*
Oil temperature
degC
50
48
52
_05
Pump speed
r/min
1900
1900
1900
Timer stroke with S/T OFF
mm
8.6
8.3
9
Oil temperature
degC
50
48
52
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001501
Pump speed
r/min
1075
1075
1075
Height
m
2000
2000
2000
Atmospheric pressure difference
kPa
-21.9
-21.9
-21.9
Atmospheric pressure difference
mmHg
-164
-164
-164
Average injection quantity
mm3/st.
37.1
37.1
37.1
Decrease qty
mm3/st.
8.2
7.2
9.2
Decrease rate
%
18
18
18
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
1075
1075
1075
Height
m
0
0
0
Atmospheric pressure difference
kPa
0
0
0
Atmospheric pressure difference
mmHg
0
0
0
Decrease qty
mm3/st.
0
0
0
Decrease rate
%
0
0
0
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1075
1075
1075
Height
m
500
500
500
Atmospheric pressure difference
kPa
-5.9
-9.2
-2.6
Atmospheric pressure difference
mmHg
-44
-69
-19
Oil temperature
degC
50
48
52
Remarks
Point of inflection
Point of inflection
_04
Pump speed
r/min
1075
1075
1075
Height
m
2000
2000
2000
Atmospheric pressure difference
kPa
-21.9
-21.9
-21.9
Atmospheric pressure difference
mmHg
-164
-164
-164
Decrease qty
mm3/st.
-8.2
-9.7
-6.7
Decrease rate
%
-18
-18
-18
Oil temperature
degC
50
48
52
Timing setting
K dimension
mm
3.1
3
3.2
KF dimension
mm
5.5
5.4
5.6
MS dimension
mm
0.8
0.7
0.9
Pre-stroke
mm
0.45
0.43
0.47
Control lever angle alpha
deg.
18
14
22
Control lever angle beta
deg.
37
32
42
Information:
Introduction
1. Type 2 fuel injector. 2. Two piece follower. 3. Nose cone. 4. Nozzle assembly.Tools are now available for the removal and installation of nose cone (3), on type 2 fuel injectors (1), when it is necessary to replace a nozzle assembly (4). Type 2 fuel injectors can be identified by the two piece follower (2).
5. 1U9395 Plate. 6. 1U8701 Socket.Use 1U9395 Plate (5) with the 6V4830 Fixture Group (not shown) and the procedure given in this instruction, for the removal and installation of nozzle assembly (4).Earlier type 2 injectors have a nose cone that has serrations on its exterior. These serrations will be damaged when the nose cone is removed. A damaged nose cone is not to be used again. A 7C9795 Nose Cone is available for use as a replacement for the original nose cone.The 7C9795 Nose Cone has a hexagon shape on its exterior. This nose cone can be installed and tightened using 1U8701 Socket (6). When the 7C9795 Nose Cone is installed, be sure to tighten it according to the procedure given in this instruction.Removal and Installation of Nose Cone and Nozzle Assembly
1. Remove the original plate from the 6V4830 Fixture Group and install 1U9395 Plate (1).2. Put injector (2) in position on the fixture group. If the exterior of the injector nose cone is a hexagon shape as shown at location (A), use the 1U8701 Socket for nose cone removal. 3. If the exterior of the nose cone has serrations as shown at location (B), use a pipe wrench, as shown, to remove the nose cone. Anytime a pipe wrench is used to remove a nose cone, the nose cone will be damaged. Never use or install a damaged nose cone on an injector. Always install a new 7C9795 Nose Cone as a replacement. 4. After the nose cone has been loosened, use a hammer and 6V4822 Tip Driver (3) to tap the nozzle assembly as shown. This is done to break the connection between the nozzle assembly and the nose cone. Be sure to use only the 6V4822 Tip Driver in this procedure, because use of a standard punch, or any other similar tool will cause damage to the nozzle tip.5. Remove the nose cone and nozzle assembly. 6. Inspect surface (C) in the injector. This is the sealing surface for the nozzle assembly. This surface must be clean and free of any scratches, nicks or burrs. Even a piece of lint from a shop towel can cause a leak and destroy nozzle performance. 7. Remove original O-ring seal (4). Install a new O-ring seal, refer to the Parts Book for the correct part number. Make sure the O-ring seal is not damaged during installation.Use a generous amount of 1P0808 Grease, or a good grade of multi-purpose lubricant, to lubricate the O-ring seal before the nose cone is installed.8. Install new nozzle assembly (5) on the injector. 9. Install and finger tighten the new 7C9795 Nose Cone on the injector. Using a
1. Type 2 fuel injector. 2. Two piece follower. 3. Nose cone. 4. Nozzle assembly.Tools are now available for the removal and installation of nose cone (3), on type 2 fuel injectors (1), when it is necessary to replace a nozzle assembly (4). Type 2 fuel injectors can be identified by the two piece follower (2).
5. 1U9395 Plate. 6. 1U8701 Socket.Use 1U9395 Plate (5) with the 6V4830 Fixture Group (not shown) and the procedure given in this instruction, for the removal and installation of nozzle assembly (4).Earlier type 2 injectors have a nose cone that has serrations on its exterior. These serrations will be damaged when the nose cone is removed. A damaged nose cone is not to be used again. A 7C9795 Nose Cone is available for use as a replacement for the original nose cone.The 7C9795 Nose Cone has a hexagon shape on its exterior. This nose cone can be installed and tightened using 1U8701 Socket (6). When the 7C9795 Nose Cone is installed, be sure to tighten it according to the procedure given in this instruction.Removal and Installation of Nose Cone and Nozzle Assembly
1. Remove the original plate from the 6V4830 Fixture Group and install 1U9395 Plate (1).2. Put injector (2) in position on the fixture group. If the exterior of the injector nose cone is a hexagon shape as shown at location (A), use the 1U8701 Socket for nose cone removal. 3. If the exterior of the nose cone has serrations as shown at location (B), use a pipe wrench, as shown, to remove the nose cone. Anytime a pipe wrench is used to remove a nose cone, the nose cone will be damaged. Never use or install a damaged nose cone on an injector. Always install a new 7C9795 Nose Cone as a replacement. 4. After the nose cone has been loosened, use a hammer and 6V4822 Tip Driver (3) to tap the nozzle assembly as shown. This is done to break the connection between the nozzle assembly and the nose cone. Be sure to use only the 6V4822 Tip Driver in this procedure, because use of a standard punch, or any other similar tool will cause damage to the nozzle tip.5. Remove the nose cone and nozzle assembly. 6. Inspect surface (C) in the injector. This is the sealing surface for the nozzle assembly. This surface must be clean and free of any scratches, nicks or burrs. Even a piece of lint from a shop towel can cause a leak and destroy nozzle performance. 7. Remove original O-ring seal (4). Install a new O-ring seal, refer to the Parts Book for the correct part number. Make sure the O-ring seal is not damaged during installation.Use a generous amount of 1P0808 Grease, or a good grade of multi-purpose lubricant, to lubricate the O-ring seal before the nose cone is installed.8. Install new nozzle assembly (5) on the injector. 9. Install and finger tighten the new 7C9795 Nose Cone on the injector. Using a
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Isuzu
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104741-5420
INJECTION-PUMP ASSEMBLY