Information injection-pump assembly
ZEXEL
104748-0310
1047480310
Rating:
Cross reference number
ZEXEL
104748-0310
1047480310
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
1500
1500
1500
Average injection quantity
mm3/st.
38.5
38
39
Difference in delivery
mm3/st.
3
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2400
2400
2400
Average injection quantity
mm3/st.
13.1
10.1
16.1
Injection timing adjustment_03
Pump speed
r/min
2125
2125
2125
Average injection quantity
mm3/st.
33.8
31.8
35.8
Injection timing adjustment_04
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
38.5
37.5
39.5
Injection timing adjustment_05
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
32.5
30.5
34.5
Injection quantity adjustment
Pump speed
r/min
2400
2400
2400
Average injection quantity
mm3/st.
13.1
11.1
15.1
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
2550
2550
2550
Average injection quantity
mm3/st.
4
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6
10
Difference in delivery
mm3/st.
2
Basic
*
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6
10
Governor adjustment_03
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
4
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
42
42
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
1250
1250
1250
Overflow quantity
cm3/min
430
298
562
Stop lever angle
Pump speed
r/min
1250
1250
1250
Pressure
kPa
510
481
539
Pressure
kgf/cm2
5.2
4.9
5.5
Basic
*
Stop lever angle_02
Pump speed
r/min
500
500
500
Pressure
kPa
294.5
265
324
Pressure
kgf/cm2
3
2.7
3.3
Stop lever angle_03
Pump speed
r/min
1250
1250
1250
Pressure
kPa
510
481
539
Pressure
kgf/cm2
5.2
4.9
5.5
Stop lever angle_04
Pump speed
r/min
2125
2125
2125
Pressure
kPa
745.5
716
775
Pressure
kgf/cm2
7.6
7.3
7.9
0000001101
Pump speed
r/min
1250
1250
1250
Timer stroke
mm
3.5
3.3
3.7
Basic
*
_02
Pump speed
r/min
1250
1250
1250
Timer stroke
mm
3.5
3.2
3.8
_03
Pump speed
r/min
1500
1500
1500
Timer stroke
mm
4.7
4.1
5.3
_04
Pump speed
r/min
2125
2125
2125
Timer stroke
mm
7.6
7
8.2
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001401
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
28
27
29
Timer stroke TA
mm
2.7
2.5
2.9
Basic
*
_02
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
28
26.5
29.5
Timer stroke TA
mm
2.7
2.4
3
_03
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
17.9
16.4
19.4
Timer stroke TA
mm
1.5
0.8
2.2
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.8
5.7
5.9
MS dimension
mm
1.5
1.4
1.6
Control lever angle alpha
deg.
30
28
32
Control lever angle beta
deg.
45
40
50
Test data Ex:
0000001801 M-CSD ADJUSTMENT
M-CSD adjustment
1. Fixing the M-CSD
(1)At roller holder advance angle a adjust the lever shaft ball pin so that it contacts the roller holder.
(2)At this time, adjust the position of the M-CSD lever (A) using adjusting screw (C) so that the clearance between the M-CSD lever (A) and the stopper (B) becomes L1. Then fix using nut (D).
TT
2. M-FICD adjustment
(1)Move the CSD lever (A) through its full stroke.
(2)Adjust screw (E) so that the control lever (G)'s position is b (the clearance between the control lever and the idling set screw is L2). Then fix using the nut (F).
TT
Pump speed NE
H = from idle to position b
----------
L1=0.5+2mm L2=4.8+-1mm a=0deg b=7deg T=6~9N-m(0.6~0.9kgf-m)
----------
L1=0.5+2mm L2=4.8+-1mm T=6~9N-m(0.6~0.9kgf-m) b=7deg
----------
L1=0.5+2mm L2=4.8+-1mm a=0deg b=7deg T=6~9N-m(0.6~0.9kgf-m)
----------
L1=0.5+2mm L2=4.8+-1mm T=6~9N-m(0.6~0.9kgf-m) b=7deg
Information:
Introduction
Tools are now available for the 6V4830 Fixture Group for removal and replacement of tappet springs on 3500 Unit Injectors.
Type 2 Fuel Injector. (1) Spring. (2) Rack Bar.
(3) 6V4830 Fixture Group. (4) 4C9279 Plate Assembly.Use fixture group (3) and plate assembly (4) along with the procedure in this instruction to remove and install tappet springs on injectors.Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.Removal and Installation of Fuel Injector Tappet Springs
Take care not to damage, drop, or jar the internal parts of the injector. Injector parts must be clean when reassembled. Place a light coating of clean diesel fuel, kerosene, or calibration fluid on the moving internal components during assembly.
* Clean the outside of the injector before disassembly. Install good O-ring seals on the injector and then install a 6V4172 Cleaning Sleeve. Wash the outside of the injector with solvents and a brush. Dry with pressure air.
Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes.The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.
1. Remove existing plate and secure plate assembly (4) to fixture group (3).2. Remove O-ring seals from the injector prior to placing injector into fixture.3. Place injector into fixture with spring up as shown. Rack bar (2) on injector is to be extended out so that it is locked into position by two pins on plate assembly (4). 4. Using the handle of the fixture group, compress injector spring (tappet) (5) so that lock pin (6) can be pushed IN to release the tappet assembly from the injector body. 5. Remove tappet assembly from the injector body. Remove and discard old spring. Place the injector plunger on a soft clean cloth to avoid handling the plunger. Excessive handling will remove the fuel on the plunger and may result in corroding the plunger if it is left out for an extended period of time.6. Install new spring on injector body. 7. Locate the punched dot (.)(7) on the top end of the gear after it is pulled out of the body. Using a yellow magic marker, paint the whole length of the tooth that is 180° opposite the punched dot.
Injector Assembly (shown without spring).8. As the tappet/plunger assembly is inserted into the body, the yellow colored tooth on the gear should be visible in the center of the slot for the tappet lock pin.
Injector Assembly (shown without spring). 9. With the colored tooth visible in the slot of the injector body, a pin or long narrow screw driver is needed to position the gear to engage rack and pinion teeth after which the tappet assembly will drop into place.10. Using the 6V4830 Fixture Group, apply pressure on tappet (5) to compress the spring so the pin pops out and locks the tappet assembly in place.11. Remove the injector from the fixture. Push and pull the
Tools are now available for the 6V4830 Fixture Group for removal and replacement of tappet springs on 3500 Unit Injectors.
Type 2 Fuel Injector. (1) Spring. (2) Rack Bar.
(3) 6V4830 Fixture Group. (4) 4C9279 Plate Assembly.Use fixture group (3) and plate assembly (4) along with the procedure in this instruction to remove and install tappet springs on injectors.Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.Removal and Installation of Fuel Injector Tappet Springs
Take care not to damage, drop, or jar the internal parts of the injector. Injector parts must be clean when reassembled. Place a light coating of clean diesel fuel, kerosene, or calibration fluid on the moving internal components during assembly.
* Clean the outside of the injector before disassembly. Install good O-ring seals on the injector and then install a 6V4172 Cleaning Sleeve. Wash the outside of the injector with solvents and a brush. Dry with pressure air.
Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes.The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.
1. Remove existing plate and secure plate assembly (4) to fixture group (3).2. Remove O-ring seals from the injector prior to placing injector into fixture.3. Place injector into fixture with spring up as shown. Rack bar (2) on injector is to be extended out so that it is locked into position by two pins on plate assembly (4). 4. Using the handle of the fixture group, compress injector spring (tappet) (5) so that lock pin (6) can be pushed IN to release the tappet assembly from the injector body. 5. Remove tappet assembly from the injector body. Remove and discard old spring. Place the injector plunger on a soft clean cloth to avoid handling the plunger. Excessive handling will remove the fuel on the plunger and may result in corroding the plunger if it is left out for an extended period of time.6. Install new spring on injector body. 7. Locate the punched dot (.)(7) on the top end of the gear after it is pulled out of the body. Using a yellow magic marker, paint the whole length of the tooth that is 180° opposite the punched dot.
Injector Assembly (shown without spring).8. As the tappet/plunger assembly is inserted into the body, the yellow colored tooth on the gear should be visible in the center of the slot for the tappet lock pin.
Injector Assembly (shown without spring). 9. With the colored tooth visible in the slot of the injector body, a pin or long narrow screw driver is needed to position the gear to engage rack and pinion teeth after which the tappet assembly will drop into place.10. Using the 6V4830 Fixture Group, apply pressure on tappet (5) to compress the spring so the pin pops out and locks the tappet assembly in place.11. Remove the injector from the fixture. Push and pull the