Information injection-pump assembly
ZEXEL
104761-4120
1047614120
Rating:
Cross reference number
ZEXEL
104761-4120
1047614120
Zexel num
Bosch num
Firm num
Name
104761-4120
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
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
750
750
750
Average injection quantity
mm3/st.
50.9
50.4
51.4
Difference in delivery
mm3/st.
3
Basic
*
Injection timing adjustment_02
Pump speed
r/min
1025
1025
1025
Average injection quantity
mm3/st.
25.6
22.1
29.1
Injection timing adjustment_03
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
45
42.5
47.5
Injection timing adjustment_04
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
51
50
52
Injection timing adjustment_05
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
45
42.5
47.5
Injection quantity adjustment
Pump speed
r/min
1025
1025
1025
Average injection quantity
mm3/st.
25.6
22.6
28.6
Difference in delivery
mm3/st.
4.5
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
3
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
10.7
8.7
12.7
Difference in delivery
mm3/st.
2
Basic
*
Governor adjustment_02
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
3
Governor adjustment_03
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
10.7
8.7
12.7
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
75
60
90
Basic
*
Speed control lever angle
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
Speed control lever angle_02
Pump speed
r/min
125
125
125
Average injection quantity
mm3/st.
5
Remarks
Magnet OFF at full-load position
Magnet OFF at full-load position
0000000901
Pump speed
r/min
750
750
750
Overflow quantity
cm3/min
330
150
510
Stop lever angle
Pump speed
r/min
250
250
250
Pressure
kPa
157
137
177
Pressure
kgf/cm2
1.6
1.4
1.8
Basic
*
Stop lever angle_02
Pump speed
r/min
250
250
250
Pressure
kPa
157
137
177
Pressure
kgf/cm2
1.6
1.4
1.8
Stop lever angle_03
Pump speed
r/min
750
750
750
Pressure
kPa
314
265
363
Pressure
kgf/cm2
3.2
2.7
3.7
Stop lever angle_04
Pump speed
r/min
1000
1000
1000
Pressure
kPa
382
333
431
Pressure
kgf/cm2
3.9
3.4
4.4
0000001101
Pump speed
r/min
750
750
750
Timer stroke
mm
0.8
0.6
1
Basic
*
_02
Pump speed
r/min
750
750
750
Timer stroke
mm
0.8
0.5
1.1
_03
Pump speed
r/min
950
950
950
Timer stroke
mm
1.6
1.2
2
0000001201
Max. applied voltage
V
16
16
16
Test voltage
V
25
24
26
Timing setting
K dimension
mm
3
2.9
3.1
KF dimension
mm
5.2
5.1
5.3
MS dimension
mm
0.9
0.8
1
Control lever angle alpha
deg.
17
13
21
Control lever angle beta
deg.
35
30
40
Information:
Illustration 15: (A) Injector sleeve. (3) Lower pilot. (36) Pipe or tubing.6. Place new injector sleeve (A) into its bore in the cylinder head. Wipe away any excess retaining compound that is either in or above the injector sleeve.7. Install lower pilot (3) into the injector sleeve. To avoid damage to the guide on the lower pilot (3), use a piece of pipe or tubing (36) with a small hammer to LIGHTLY tap the lower pilot. This will ensure that the new injector sleeve is fully seated in the cylinder head.Remove lower pilot (3).
Illustration 16: (14) Roller expander. (32) Mandrel.8. Place a coating of clean engine oil on 4C-6730 Roller Expander (14). Ensure the rollers are completely covered with oil.9. Pull and hold mandrel (32) out of the roller expander (14) as far as possible. Then completely insert the roller expander into the injector sleeve.10. Place a torque wrench with a 11 mm socket on the hex portion of 4C-6730 Roller Expander mandrel. Turn the torque wrench in a clockwise (CW) direction in order to achieve a torque of 11 N m (100 lb in). If torque stops increasing before 11 N m (100 lb in) the sleeve is not hard enough or the bore is oversized in the head.
To ensure that accurate torque is achieved, a calibrated 4C-6936 Torque Wrench or equivalent is required.
11. When the specified torque is reached, stop turning the roller expander in the clockwise (CW) direction. Now turn the roller expander in the counterclockwise (CCW) direction until it is loose in the injector sleeve.Remove 4C-6730 Roller Expander from the injector sleeve.12. Wipe the roller expander, especially the rollers, to remove any traces of 7M-7456 Bearing Mount or Loctite® 609 that may have built up from the injector sleeve. When usage of 4C-6730 Roller Expander is completed, clean it thoroughly using either 1U-8803 Cleaner Concentrate or 8T-9011 Component Cleaner. After the cleaning, place a generous coat of either 1U-8265 Penetrating Oil or 1U-8809 Rust Preventive on the roller expander. Place it in its storage case.
Illustration 17: (A) Injector sleeve. (13) Driver. (15) Guide bushing. Wage/flaring assembly: (8) Set screw. (9) Bottom swage. (11) Flare tool.13. Install 4C-6591 Bottom Swage (9) in 9U-6856 Flare Tool (11) using 4C-5502 Set Screw (8).14. Slide same guide bushing (15) used previously onto 9U-6856 Flare Tool (11).
Some 9U-6856 Flare Tools have their part number stamped on the turn which fits into the guide bushing. This arrangement interferes with the fit. Before the first tool use, the part number should be filed down as necessary in order to permit fit of the flare tool in the guide bushing.
15. Use 5P-3931 Anti-seize Compound, 6V-4876 Molykote Paste Lubricant, or grease to lubricate the swage/flaring assembly. Place it into the sleeve with the flare tool prying notch facing either opening between the valve springs. This will allow access for removal of the swage/flaring assembly.16. Place 9U-6857 Driver (13) on 9U-6856 Flare Tool (11).17. Use a hammer to drive down the swage/flaring assembly until
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Komatsu
Komatsu
104761-4120
INJECTION-PUMP ASSEMBLY