Rating:
Information injection-pump assembly
ZEXEL
104740-2491
1047402491
Cross reference number
ZEXEL
104740-2491
1047402491
Zexel num
Bosch num
Firm num
Name
104740-2491
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
(Solenoid timer adjustment condition)
With S/T O-ring; S/T OFF. OFF
With S/T O-ring; S/T OFF. OFF
Injection timing adjustment
Pump speed
r/min
700
700
700
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
33.5
33.1
33.9
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
50
48
52
Remarks
Full
Full
Injection timing adjustment_02
Pump speed
r/min
900
900
900
Boost pressure
kPa
40
38.7
41.3
Boost pressure
mmHg
300
290
310
Average injection quantity
mm3/st.
45
44.6
45.4
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
50
48
52
Remarks
CBS
CBS
Injection timing adjustment_03
Pump speed
r/min
500
500
500
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
38.2
33.7
42.7
Oil temperature
degC
48
46
50
Injection timing adjustment_04
Pump speed
r/min
600
600
600
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
33.4
30.9
35.9
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
700
700
700
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
33.5
32.5
34.5
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
Full
Full
Injection timing adjustment_06
Pump speed
r/min
900
900
900
Boost pressure
kPa
40
38.7
41.3
Boost pressure
mmHg
300
290
310
Average injection quantity
mm3/st.
45
44
46
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
CBS
CBS
Injection timing adjustment_07
Pump speed
r/min
1200
1200
1200
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
54.8
51.8
57.8
Oil temperature
degC
50
48
52
Injection timing adjustment_08
Pump speed
r/min
1800
1800
1800
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
52.6
49.6
55.6
Oil temperature
degC
50
48
52
Injection timing adjustment_09
Pump speed
r/min
2200
2200
2200
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
48
44.5
51.5
Oil temperature
degC
52
50
54
Injection timing adjustment_10
Pump speed
r/min
2400
2400
2400
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
45.6
42.1
49.1
Oil temperature
degC
52
50
54
Injection quantity adjustment
Pump speed
r/min
2550
2550
2550
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
37.5
36.5
38.5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_02
Pump speed
r/min
2550
2550
2550
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
37.5
35.5
39.5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2700
2700
2700
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
21.4
13.4
29.4
Difference in delivery
mm3/st.
5.5
Oil temperature
degC
55
52
58
Injection quantity adjustment_04
Pump speed
r/min
2950
2950
2950
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
6
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
400
400
400
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
10.5
9.5
11.5
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
400
400
400
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
10.5
8.5
12.5
Difference in delivery
mm3/st.
2.5
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_03
Pump speed
r/min
600
600
600
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
5
Oil temperature
degC
50
48
52
Timer adjustment
Pump speed
r/min
100
100
100
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
68
63
73
Basic
*
Oil temperature
degC
48
46
50
Remarks
IDLE
IDLE
Timer adjustment_02
Pump speed
r/min
100
100
100
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
68
63
73
Oil temperature
degC
48
46
50
Speed control lever angle
Pump speed
r/min
400
400
400
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
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
900
900
900
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Overflow quantity with S/T ON
cm3/min
380
250
510
Oil temperature
degC
50
48
52
Remarks
MEASURE
MEASURE
Stop lever angle
Pump speed
r/min
900
900
900
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Pressure with S/T ON
kPa
353
324
382
Pressure with S/T ON
kgf/cm2
3.6
3.3
3.9
Pressure with S/T OFF
kPa
412
383
441
Pressure with S/T OFF
kgf/cm2
4.2
4
4.4
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
Stop lever angle_02
Pump speed
r/min
600
600
600
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Pressure with S/T OFF
kPa
343
304
382
Pressure with S/T OFF
kgf/cm2
3.5
3.1
3.9
Oil temperature
degC
50
48
52
Stop lever angle_03
Pump speed
r/min
900
900
900
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Pressure with S/T OFF
kPa
411.5
382
441
Pressure with S/T OFF
kgf/cm2
4.2
3.9
4.5
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_04
Pump speed
r/min
1400
1400
1400
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Pressure with S/T OFF
kPa
520
481
559
Pressure with S/T OFF
kgf/cm2
5.3
4.9
5.7
Oil temperature
degC
50
48
52
Stop lever angle_05
Pump speed
r/min
2200
2200
2200
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Pressure with S/T OFF
kPa
696
647
745
Pressure with S/T OFF
kgf/cm2
7.1
6.6
7.6
Oil temperature
degC
52
50
54
0000001101
Pump speed
r/min
900
900
900
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Timer stroke with S/T ON
mm
1
0.5
1.5
Timer stroke with S/T OFF
mm
2.2
2
2.4
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_02
Pump speed
r/min
600
600
600
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Timer stroke with S/T OFF
mm
0.7
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
900
900
900
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Timer stroke with S/T ON
mm
1
0.4
1.6
Timer stroke with S/T OFF
mm
2.2
1.9
2.5
Basic
*
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
1400
1400
1400
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Timer stroke with S/T OFF
mm
5.1
4.7
5.5
Oil temperature
degC
50
48
52
_05
Pump speed
r/min
2200
2200
2200
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Timer stroke with S/T OFF
mm
8.15
7.7
8.6
Oil temperature
degC
52
50
54
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
6.29
6.19
6.39
MS dimension
mm
0.9
0.8
1
BCS stroke
mm
4.6
4.4
4.8
Control lever angle alpha
deg.
25
21
29
Control lever angle beta
deg.
42
37
47
Test data Ex:
0000001801 POTENTIOMETER ADJUSTMENT
Potentiometer adjustment (dummy bolt type)
N:Pump speed
Q:Injection quantity
V:Output voltage
Vi:Applied voltage
A:Standard point
B:Check.
C/L: control lever angle
I:Idling lever position
F:Full speed lever position
E:Conversion point
C:Lever position
G:From idle
H:ON-->OFF
M:OFF-->ON
J:Connecting diagram for the potentiometer
K:Output
O:Output when (2) and (3) connected.
P:When (4) or (6) connected: switch OFF to ON.
R:When (4) or (5) connected: switch ON to OFF.
----------
----------
N1=700r/min Q1=17.0+-1.0mm3/st V1=3.86+-0.03V V2=(1.34+-0.4V) V3=(8.34+-1.47V) C1=(15.1deg) C2=0deg C3=42+-5deg Vi=10V C4=(5+-3deg) C5=(21.5++deg)
----------
----------
N1=700r/min Q1=17.0+-1.0mm3/st V1=3.86+-0.03V V2=(1.34+-0.4V) V3=(8.34+-1.47V) C1=(15.1deg) C2=0deg C3=42+-5deg Vi=10V C4=(5+-3deg) C5=(21.5++deg)
0000001901 STARTING I/Q ADJUSTMENT
Starting injection quantity adjustment
Adjust adjusting bolt so that the starting injection quantity is within the standard.
Fix using nut.
(A): Lock nut.
(B): Stopping lever
(C): Adjustment bolt
----------
----------
L=5.9~8.2mm
----------
----------
L=5.9~8.2mm
0000002001 M-CSD ADJUSTMENT
M-CSD adjustment
1. Fixing intermediate lever screw (A) [roller (E) must not contact intermediate lever (D)]
(1)Hold the control lever (C) in the idling position.
(2)With intermediate lever (D) and bracket (K)'s stopper contacting, fix nut (B) at the position where the clearance between the intermediate lever screw (A) and the control lever (C) is L1.
2. Fixing the stopper (I)
(1)Pull the CSD lever F in the direction X until it contacts the stopper I.
(2)With these types of timers, tighten the socket head bolt (J) at the position where the advance angle is L2.
3. Screw (G) adjustment
(1)Pull the CSD lever F in the direction X until it contacts the stopper I and adjust using screw G so that the control lever shim thickness is L3. Then fix using nut H. Pin E is fully above the elongated hole (R).
(2)When the CSD lever (F) is returned, there can be a clearance between (E)'s pin and (D)'s intermediate lever. Also, to fine adjust the lever position, use screw (A) (but you must maintain clearance L1).
----------
L1=1~2mm L2=0.82--mm L3=11.0+-0.05mm R=45.5mm
----------
T1=6~9N-m(0.6~0.9kgf-m) T2=4.9~7N-m(0.5~0.7kgf-m) T3=2~2.9N-m(0.2~0.3kgf-m) R=45.5mm L1=1~2mm L2=0.82--mm L3=11.0+-0.05mm
----------
L1=1~2mm L2=0.82--mm L3=11.0+-0.05mm R=45.5mm
----------
T1=6~9N-m(0.6~0.9kgf-m) T2=4.9~7N-m(0.5~0.7kgf-m) T3=2~2.9N-m(0.2~0.3kgf-m) R=45.5mm L1=1~2mm L2=0.82--mm L3=11.0+-0.05mm
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104740-2491
INJECTION-PUMP ASSEMBLY