104740-2500 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047402500


104740-2500 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 104740-2500 1047402500

Cross reference number

ZEXEL 104740-2500 1047402500


Zexel num
Bosch num
Firm num
Name
104740-2500 
 
   
INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions
Test oil
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
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
(Solenoid timer adjustment condition)
With S/T O-ring; S/T OFF.
  OFF
Injection timing adjustment
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   35.3 34.9 35.7
Difference in delivery mm3/st.   3
Basic   *
Oil temperature degC   50 48 52
Injection timing adjustment_02
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   30.1 24.6 35.6
Oil temperature degC   48 46 50
Injection timing adjustment_03
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   29.8 27.3 32.3
Oil temperature degC   50 48 52
Injection timing adjustment_04
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   31.2 28.2 34.2
Oil temperature degC   50 48 52
Injection timing adjustment_05
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   35.3 34.3 36.3
Difference in delivery mm3/st.   3.5
Basic   *
Oil temperature degC   50 48 52
Injection timing adjustment_06
Pump speed r/min   1800 1800 1800
Average injection quantity mm3/st.   32.6 30.1 35.1
Oil temperature degC   50 48 52
Injection timing adjustment_07
Pump speed r/min   2400 2400 2400
Average injection quantity mm3/st.   33.6 30.1 37.1
Oil temperature degC   52 50 54
Injection quantity adjustment
Pump speed r/min   2700 2700 2700
Average injection quantity mm3/st.   14 12 16
Difference in delivery mm3/st.   4.5
Basic   *
Oil temperature degC   55 52 58
Injection quantity adjustment_02
Pump speed r/min   2700 2700 2700
Average injection quantity mm3/st.   14 10.5 17.5
Difference in delivery mm3/st.   5
Basic   *
Oil temperature degC   55 52 58
Injection quantity adjustment_03
Pump speed r/min   2800 2800 2800
Average injection quantity mm3/st.   5
Oil temperature degC   55 52 58
Governor adjustment
Pump speed r/min   350 350 350
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   350 350 350
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   700 700 700
Average injection quantity mm3/st.   5
Oil temperature degC   50 48 52
Boost compensator adjustment
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   15.1 8.6 21.6
Oil temperature degC   50 48 52
Lever angle (shim thickness) mm   8.9 8.85 8.95
Remarks
From idle
 
Boost compensator adjustment_02
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   10.3 3.3 17.3
Oil temperature degC   50 48 52
Lever angle (shim thickness) mm   8.9 8.85 8.95
Remarks
From idle
 
Timer adjustment
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   60 50 70
Basic   *
Oil temperature degC   48 46 50
Remarks
Full
 
Timer adjustment_02
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   60 50 70
Oil temperature degC   48 46 50
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
 
0000000901
Pump speed r/min   1000 1000 1000
Overflow quantity with S/T ON cm3/min   440 310 570
Oil temperature degC   50 48 52
Stop lever angle
Pump speed r/min   1000 1000 1000
Pressure with S/T ON kPa   422 393 451
Pressure with S/T ON kgf/cm2   4.3 4 4.6
Pressure with S/T OFF kPa   324 275 373
Pressure with S/T OFF kgf/cm2   3.3 2.8 3.8
Basic   *
Oil temperature degC   50 48 52
Remarks
ON
 
Stop lever angle_02
Pump speed r/min   1000 1000 1000
Pressure with S/T ON kPa   421.5 382 461
Pressure with S/T ON kgf/cm2   4.3 3.9 4.7
Pressure with S/T OFF kPa   323.5 265 382
Pressure with S/T OFF kgf/cm2   3.3 2.7 3.9
Basic   *
Oil temperature degC   50 48 52
Stop lever angle_03
Pump speed r/min   1800 1800 1800
Pressure with S/T ON kPa   588.5 549 628
Pressure with S/T ON kgf/cm2   6 5.6 6.4
Oil temperature degC   50 48 52
Stop lever angle_04
Pump speed r/min   2400 2400 2400
Pressure with S/T ON kPa   725.5 686 765
Pressure with S/T ON kgf/cm2   7.4 7 7.8
Oil temperature degC   52 50 54
0000001101
Pump speed r/min   1000 1000 1000
Timer stroke with S/T ON mm   3.1 2.7 3.5
Timer stroke with S/T OFF mm   1.9 1.7 2.1
Basic   *
Oil temperature degC   50 48 52
Remarks
OFF
 
_02
Pump speed r/min   1000 1000 1000
Timer stroke with S/T ON mm   3.1 2.6 3.6
Timer stroke with S/T OFF mm   1.9 1.6 2.2
Basic   *
Oil temperature degC   50 48 52
_03
Pump speed r/min   1800 1800 1800
Timer stroke with S/T OFF mm   5.6 5.1 6.1
Oil temperature degC   50 48 52
_04
Pump speed r/min   2400 2400 2400
Timer stroke with S/T OFF mm   7.35 6.9 7.8
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   6.78 6.68 6.88
MS dimension mm   0.8 0.7 0.9
Control lever angle alpha deg.   25 23 27
Control lever angle beta deg.   44 39 49

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Test data 104740-2500
Adjustment of the potentiometer At pump speed N and with the control lever angle at a from the idle position (clearance L), convert the injection quantity obtained to a voltage value using the graph and adjust the potentiometer. Vo:Output voltage Q:Injection quantity A:Performance standards C:Position of the control lever G:Idle H:Full speed E:J = formula V+-0.03 = 0.13121Q+2.4787 K = Vi: applied voltage X:Injection quantity (mm3/st) Y:Voltage (V) M:Connecting diagram for the potentiometer O:Output P:Output when (2) and (3) connected.
----------
N=700(r/min) a=13.9(deg) L=8.9+-0.05(mm) Vi=10(V)
----------
V1=(1.7--(V)) V2=9.96++(V) K=Vi=10(V)

0000001901 W-CSD ADJUSTMENT

Test data 104740-2500
Adjustment of the W-CSD 1. Adjustment of the advance angle of the timer (1)Determine the timer advance angle from the figure (Q)'s graph. (2)(1) Adjust using the screw (I) so that the timer advance angle determined in item (1) is obtained. 2. Intermediate lever position setting [refer to fig (O), (P)] (1)Insert a block gauge L1 between the idling set screw (H) and the control lever (G). (2)Insert a shim thickness L2+-0.05 mm between the intermediate lever (D) and the intermediate lever bracket (E). Hold control lever (G) against screw (F) then fix the nut. 3. W-CSD lever adjustment [refer to fig (O) and fig (P)] (1)Insert a block gauge thickness L3 determined from the graph Q (L-theta) between the idling set screw (H) and the control lever (G). (2)Adjust the screw (B) until the screw (F) contacts the control lever (G). Then fix locknut (A). Note The temperature of the wax at adjustment must not exceed a. X:Temperature theta (deg C) Y1:Timer stroke TA (mm) Y2:Control lever L dimension (mm; control lever position) Graph TA-theta theta (deg C) <= 10: TA = 0.82 10 <= theta (deg C) <= 20: TA = -0.027 theta + 1.09 20 <= theta (deg C) <= 40: TA = -0.0275 theta + 1.1 L-theta graph theta (deg C) <= 10: L = 3.9 10 <= theta (deg C) <= 30 L = -0.09 theta + 4.8 30 <= theta (deg C) <= 54.3 L = -0.086 theta + 4.68
----------
L1=3.0+-0.05(mm) L2=5.3(mm) L3=L+-0.5(mm) a=30(degC)
----------
L1=3.0+-0.05(mm) L2=5.3(mm)

0000002001 DASHPOT ADJUSTMENT

Test data 104740-2500
Adjustment of the dash pot 1. Insert a block gauge L (thickness gauge) between the idle set screw (C) and the control lever (D). 2. In the above condition, adjust so that the dashpot adjusting screw (A) contacts the pushrod. Then, fix using the locknut (B) (Tightening torque T3). 3. Ensure the adjusting screw or dashpot does not stick or come loose. 4. Confirm that the control lever returns to the idling position. (E) 6 locations
----------
L=6.0+-0.05(mm) T3=4.9~6.9(N-m)(0.5~0.7(kgf-m))
----------
T1=15.0~20.0(N-m)(1.5~2.0(kgf-m)) T2=6.0~0.9(N-m)(0.6~0.9(kgf-m)) SW1=SW22(mm) SW2=SW10(mm) L=6.0+-0.05(mm)




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