Information injection-pump assembly
ZEXEL
104780-9170
1047809170
Rating:
Cross reference number
ZEXEL
104780-9170
1047809170
Zexel num
Bosch num
Firm num
Name
104780-9170
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)
Right R
Right R
(Solenoid timer adjustment condition)
OFF
Injection timing adjustment
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
44
43.5
44.5
Difference in delivery
mm3/st.
4
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
40.8
38.3
43.3
Oil temperature
degC
48
46
50
Injection timing adjustment_03
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
44
43
45
Difference in delivery
mm3/st.
4.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
2000
2000
2000
Average injection quantity
mm3/st.
46.7
43.7
49.7
Oil temperature
degC
50
48
52
Injection quantity adjustment
Pump speed
r/min
2550
2550
2550
Average injection quantity
mm3/st.
10.9
8.9
12.9
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_02
Pump speed
r/min
2700
2700
2700
Average injection quantity
mm3/st.
5
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2350
2350
2350
Average injection quantity
mm3/st.
39.7
39.7
39.7
Oil temperature
degC
52
50
54
Injection quantity adjustment_04
Pump speed
r/min
2550
2550
2550
Average injection quantity
mm3/st.
10.9
8.4
13.4
Basic
*
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
7.7
5.7
9.7
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
7.7
5.2
10.2
Difference in delivery
mm3/st.
2.5
Basic
*
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60
45
80
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
45
80
Oil temperature
degC
48
46
50
Remarks
Full
Full
Speed control lever angle
Pump speed
r/min
350
350
350
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
1100
1100
1100
Overflow quantity
cm3/min
450
320
580
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
1300
1300
1300
Pressure with S/T ON
kPa
549
510
588
Pressure with S/T ON
kgf/cm2
5.6
5.2
6
Pressure with S/T OFF
kPa
471
442
500
Pressure with S/T OFF
kgf/cm2
4.8
4.5
5.1
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
Stop lever angle_02
Pump speed
r/min
1300
1300
1300
Pressure with S/T OFF
kPa
471
432
510
Pressure with S/T OFF
kgf/cm2
4.8
4.4
5.2
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
Stop lever angle_03
Pump speed
r/min
2150
2150
2150
Pressure with S/T OFF
kPa
647
608
686
Pressure with S/T OFF
kgf/cm2
6.6
6.2
7
Oil temperature
degC
52
50
54
0000001101
Pump speed
r/min
1300
1300
1300
Timer stroke with S/T ON
mm
3.6
3.2
4
Timer stroke with S/T OFF
mm
2.1
1.9
2.3
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_02
Pump speed
r/min
1100
1100
1100
Timer stroke with S/T OFF
mm
1.1
0.6
1.6
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1300
1300
1300
Timer stroke with S/T ON
mm
3.6
3.1
4.1
Timer stroke with S/T OFF
mm
2.1
1.8
2.4
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_04
Pump speed
r/min
2150
2150
2150
Timer stroke with S/T OFF
mm
5.6
5
6.2
Oil temperature
degC
52
50
54
_05
Pump speed
r/min
2500
2500
2500
Timer stroke with S/T OFF
mm
6.1
5.6
6.5
Oil temperature
degC
55
52
58
0000001201
Max. applied voltage
V
16
16
16
Test voltage
V
25
24
26
0000001401
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
25.5
25
26
Timer stroke TA
mm
1.8
1.8
1.8
Timer stroke variation dT
mm
0.3
0.1
0.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_02
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
25.5
24.5
26.5
Timer stroke variation dT
mm
0.3
0
0.6
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_03
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
17
14.5
19.5
Timer stroke variation dT
mm
0.9
0.5
1.3
Oil temperature
degC
50
48
52
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.8
5.7
5.9
MS dimension
mm
0.9
0.8
1
Pre-stroke
mm
0.1
0.08
0.12
Control lever angle alpha
deg.
25
21
29
Control lever angle beta
deg.
36
31
41
Test data Ex:
0000001801 POTENTIOMETER ADJUSTMENT
Note: Potentiometer (P/M) adjustment method
Substitute the actual measurement of the angle a of each I/P in the following formula and determine the P/M output adjustment y (V).
When the angle a <= c: y = 7.23
When c < angle a < d: y = 7.23+( angle a -33) x 0.133
When d <alpha <e: y=7.97
Reference: Idle position and full speed position output voltages are V6 (idle) and V7 (full speed).
A:Potentiometer standards
B:ON, OFF switch standard
G:ON-->OFF
D:OFF-->ON
E:Adjusting point
F:Checking point
P:Boost pressure
Vi:Applied voltage
C1:Full-speed
C2:Idle
Q:Injection quantity
N:Pump speed
V:Output voltage
C:Control lever angle
----------
a=-deg c=33deg d=39deg e=-deg P1=-kPa P2=-mmHg V6=1.6+-0.6V V7=7.6+-0.4V
----------
V1=a+-0.03V V2=1.6+-0.6V V3=-V V4=-V V5=-V C3=0.1~10.2deg C4=(19.4)deg Vi=10V P1=-kPa P2=-mmHg
----------
a=-deg c=33deg d=39deg e=-deg P1=-kPa P2=-mmHg V6=1.6+-0.6V V7=7.6+-0.4V
----------
V1=a+-0.03V V2=1.6+-0.6V V3=-V V4=-V V5=-V C3=0.1~10.2deg C4=(19.4)deg Vi=10V P1=-kPa P2=-mmHg
Information:
Problem 4
The starting motor remains engaged or the starting motor continues to run after the engine is running.
Check the components of the starting circuit.
Measure the voltages at terminal (TS-26) of the junction box and at terminal (ESS-12) of the electronic speed switch while the engine is running. Result
The voltage at both terminals is zero volts.The problem is in the starting motor (SM), the pinion solenoid (PS), or the magnetic switch (MS). Repair the faulty component. STOP.
The voltage at terminal (ESS-12) is between 15 volts and 32 volts. The voltage at terminal (TS-26) is above 15 volts or below 15 volts but not zero volts.The contacts for the crank terminate (CT) switch of the electronic speed switch (ESS) do not open. Refer to Testing and Adjusting, "Crank Terminate Speed Calibration". If the ESS is not faulty, check diode (D3). Refer to Testing and Adjusting, "Diode Test".
The voltage at both terminals is between 15 volts and 32 volts.The voltage at the terminals is greater than zero volts. During the normal operation of the start/stop switch, the start/stop switch opens across the contacts of the START position. Also, the start/stop switch closes across the contacts of the RUN position. The switch closes when the toggle or the lever of the switch moves from the START position to the RUN position. Repair the switch if the voltage is zero.
The voltage at terminal (ESS-12) is not zero.The CT contacts of the ESS are not opening. Refer to Testing and Adjusting, "Crank Terminate Speed Calibration".Problem 5
The engine shutdown occurs after the engine runs for more than 3 minutes.
Check the overspeed setting on the electronic speed switch (ESS).
Observe the indicator lamp on the ESS.
Reset the air shutoff lever, if equipped. Result
The indicator lamp on the ESS is turned on.Overspeed is indicated as the cause of the engine shutdown. Press the "RESET" button of the ESS. Find the cause of the overspeed. Refer to Testing and Adjusting, "Overspeed Verification Test" and Testing and Adjusting, "Overspeed Calibration". If the overspeed is adjusted properly and the problem persists, check the shielded cable. Only the shield should be connected to terminal 2 on the ESS. STOP.
The indicator lamp is turned off.Go to Step 2.
Check the oil pressure switches.
Connect a jumper between terminals (TS-9) and (TS-14) of the junction box.
Start the engine. Result
The engine starts and the engine runs.The problem is in the oil pressure switches. Go to Step 7 of "Problem 3".
The engine starts but engine shutdown occurs immediately.Go to Step 1 of "Problem 3".
The engine starts and the engine runs but engine shutdown occurs after the engine runs for more than 3 minutes.Go to Step 3.
The engine cranks but the engine does not start.Go to Step 1 of "Problem 1".Note: If the water temperature contactor switch causes overheating go to Step 8 of "Problem 1". If the water temperature contactor switch is not the problem, go to Step 1of "Problem 1".
Check the slave relay (SR1).
Disconnect the jumper from terminals (TS-9) and (TD-14).
Connect a jumper between terminals (TS-14) and
The starting motor remains engaged or the starting motor continues to run after the engine is running.
Check the components of the starting circuit.
Measure the voltages at terminal (TS-26) of the junction box and at terminal (ESS-12) of the electronic speed switch while the engine is running. Result
The voltage at both terminals is zero volts.The problem is in the starting motor (SM), the pinion solenoid (PS), or the magnetic switch (MS). Repair the faulty component. STOP.
The voltage at terminal (ESS-12) is between 15 volts and 32 volts. The voltage at terminal (TS-26) is above 15 volts or below 15 volts but not zero volts.The contacts for the crank terminate (CT) switch of the electronic speed switch (ESS) do not open. Refer to Testing and Adjusting, "Crank Terminate Speed Calibration". If the ESS is not faulty, check diode (D3). Refer to Testing and Adjusting, "Diode Test".
The voltage at both terminals is between 15 volts and 32 volts.The voltage at the terminals is greater than zero volts. During the normal operation of the start/stop switch, the start/stop switch opens across the contacts of the START position. Also, the start/stop switch closes across the contacts of the RUN position. The switch closes when the toggle or the lever of the switch moves from the START position to the RUN position. Repair the switch if the voltage is zero.
The voltage at terminal (ESS-12) is not zero.The CT contacts of the ESS are not opening. Refer to Testing and Adjusting, "Crank Terminate Speed Calibration".Problem 5
The engine shutdown occurs after the engine runs for more than 3 minutes.
Check the overspeed setting on the electronic speed switch (ESS).
Observe the indicator lamp on the ESS.
Reset the air shutoff lever, if equipped. Result
The indicator lamp on the ESS is turned on.Overspeed is indicated as the cause of the engine shutdown. Press the "RESET" button of the ESS. Find the cause of the overspeed. Refer to Testing and Adjusting, "Overspeed Verification Test" and Testing and Adjusting, "Overspeed Calibration". If the overspeed is adjusted properly and the problem persists, check the shielded cable. Only the shield should be connected to terminal 2 on the ESS. STOP.
The indicator lamp is turned off.Go to Step 2.
Check the oil pressure switches.
Connect a jumper between terminals (TS-9) and (TS-14) of the junction box.
Start the engine. Result
The engine starts and the engine runs.The problem is in the oil pressure switches. Go to Step 7 of "Problem 3".
The engine starts but engine shutdown occurs immediately.Go to Step 1 of "Problem 3".
The engine starts and the engine runs but engine shutdown occurs after the engine runs for more than 3 minutes.Go to Step 3.
The engine cranks but the engine does not start.Go to Step 1 of "Problem 1".Note: If the water temperature contactor switch causes overheating go to Step 8 of "Problem 1". If the water temperature contactor switch is not the problem, go to Step 1of "Problem 1".
Check the slave relay (SR1).
Disconnect the jumper from terminals (TS-9) and (TD-14).
Connect a jumper between terminals (TS-14) and
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104780-9170
INJECTION-PUMP ASSEMBLY