104742-7490 ZEXEL test values diesel fuel-injection equipment 28/10/24 18:10:11 Page 1

ZEXEL Ass'y No. 104742-7490

Bosch Ass'y No. 9 460 614 955
Bosch Typecode
Engine Type 4TNE98
Manufacturer YANMAR
Edition date 20/06/05 (1)

1 Adjustment conditions
CAT Designation Unit Set value min. max. Actual values OT
Test oil ISO4113orSAEJ967
d
1404 Test oil
P Test oil temperature degC 45 45 50
Nozzle 105780-0060
Bosch type code NP-DN0SD1510
Nozzle holder 105780-2150
P Opening pressure MPa 13 13 13.3
P Opening pressure kgf/cm2 133 133 136
Injection pipe 157805-7320
P Injection pipe mm 2-6-450
Inside diameter - outside diameter - length (mm)
Joint assembly 157641-4720
Tube assembly 157641-4020
P Transfer pump pressure kPa 20 20 20
P Transfer pump pressure kgf/cm2 0.2 0.2 0.2
Direction of rotation (viewed from drive side) R
Right

2 Adjustment specification
2.1 Full load delivery
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 850 850 850
S Average injection quantity mm3/st. 65.1 64.6 65.6
S Difference in delivery mm3/st. 5 5
P Basic *
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 500 500 500
C Average injection quantity mm3/st. 60.6 55.1 66.1
About
P Oil temperature degC 48 46 50
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 850 850 850
C Average injection quantity mm3/st. 65.1 64.1 66.1
C Difference in delivery mm3/st. 5.5 5.5
P Basic *
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1150 1150 1150
C Average injection quantity mm3/st. 62.9 59.4 66.4
About
P Oil temperature degC 50 48 52
2.2 Governing
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1313 1313 1313
S Average injection quantity mm3/st. 19.7 15.2 24.2
S Difference in delivery mm3/st. 5 5
P Basic *
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1400 1400 1400
C Average injection quantity mm3/st. 5 5
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1313 1313 1313
C Average injection quantity mm3/st. 19.7 14.7 24.7
C Difference in delivery mm3/st. 5.5 5.5
P Basic *
P Oil temperature degC 50 48 52
2.3 Idle
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 405 405 405

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
104742-7490 ZEXEL test values diesel fuel-injection equipment 28/10/24 18:10:11 Page 2

S Average injection quantity mm3/st. 9.8 7.8 11.8

S Difference in delivery mm3/st. 2 2
P Basic *
P Oil temperature degC 48 46 50
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 405 405 405
C Average injection quantity mm3/st. 9.8 7.3 12.3
C Difference in delivery mm3/st. 2 2
P Basic *
P Oil temperature degC 48 46 50
2.4 Start
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
S Average injection quantity mm3/st. 67.3 62.3 72.3
P Basic *
P Oil temperature degC 48 46 50
Remarks
Full
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
C Average injection quantity mm3/st. 67.3 62.3 72.3
P Oil temperature degC 48 46 50
Remarks
Full
2.5 Stop
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 405 405 405
C Average injection quantity mm3/st. 0 0 0
P Oil temperature degC 48 46 50
Remarks
Magnet OFF at idling position
2.6 Overflow
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
C Overflow quantity cm3/min 440 310 570
About
P Oil temperature degC 50 48 52
2.7 Pump chamber pressure
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
S Pressure kPa 637 608 666
S Pressure kgf/cm2 6.5 6.2 6.8
P Basic *
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
C Pressure kPa 637 598 676
C Pressure kgf/cm2 6.5 6.1 6.9
P Basic *
P Oil temperature degC 50 48 52
2.8 Timer
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
S Timer stroke mm 2.5 2.3 2.7
P Basic *
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
C Timer stroke mm 2.5 2.1 2.9
P Basic *
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1150 1150 1150
C Timer stroke mm 3.3 2.7 3.9
About
P Oil temperature degC 50 48 52
2.9 Magnet
CAT Designation Unit Set value min. max. Actual values OT
C Max. applied voltage V 8 8 8
P Test voltage V 13 12 14
2.10 Additional device adjustment

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.10.1 Additional device 1

Name STOP LEVER ADJUSTMENT
L=15.0~18.5mm
T=6~9Nm(0.6~0.9kgfm)

Adjustment of the stop lever

Adjust adjusting bolt (B) so that the starting injection quantity is within the standard.
Fix using nut.
(A) = adjusting nut
(C) = starting injection quantity adjusting lever

3 Assembly dimension
CAT Designation Unit Set value min. max. Actual values OT
S K dimension mm 3.1 3 3.2
S KF dimension mm 5.3 5.2 5.4
S MS dimension mm 1.8 1.7 1.9
S Control lever angle alpha deg. 16 12 20
S Control lever angle beta deg. 29 24 34
About

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)