Rating:
Information injection-pump assembly
ZEXEL
104740-2393
1047402393
Cross reference number
ZEXEL
104740-2393
1047402393
Zexel num
Bosch num
Firm num
Name
104740-2393
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)
Excluding timer, pump chamber pressure ON
Excluding timer, pump chamber pressure ON
Injection timing adjustment
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
36.6
36.2
37
Difference in delivery
mm3/st.
3
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2700
2700
2700
Average injection quantity
mm3/st.
14
11.5
16.5
Injection timing adjustment_03
Pump speed
r/min
2400
2400
2400
Average injection quantity
mm3/st.
36.1
32.6
39.6
Injection timing adjustment_04
Pump speed
r/min
1800
1800
1800
Average injection quantity
mm3/st.
37.3
34.8
39.8
Injection timing adjustment_05
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
36.6
35.7
37.5
Injection timing adjustment_06
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
32.6
29.6
35.6
Injection timing adjustment_07
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
33.3
30.8
35.8
Injection timing adjustment_08
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
35.1
29.6
40.6
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
*
Injection quantity adjustment_02
Pump speed
r/min
2800
2800
2800
Average injection quantity
mm3/st.
5
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
*
Governor adjustment_02
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
5
Governor adjustment_03
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
10.5
9
12
Boost compensator adjustment
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
20.5
14
27
Remarks
From idle
From idle
Boost compensator adjustment_02
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
15.2
8.2
22.2
Remarks
From idle
From idle
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60
50
70
Basic
*
Remarks
Full
Full
Speed control lever angle
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
0000000901
Pump speed
r/min
1000
1000
1000
Overflow quantity
cm3/min
438
306
570
Stop lever angle
Pump speed
r/min
1000
1000
1000
Pressure with S/T ON
kPa
421.5
392
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
*
Stop lever angle_02
Pump speed
r/min
1000
1000
1000
Pressure with S/T ON
kPa
421.5
392
451
Pressure with S/T ON
kgf/cm2
4.3
4
4.6
Stop lever angle_03
Pump speed
r/min
1800
1800
1800
Pressure with S/T ON
kPa
588.5
559
618
Pressure with S/T ON
kgf/cm2
6
5.7
6.3
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
0000001101
Pump speed
r/min
1000
1000
1000
Timer stroke with S/T ON
mm
3.1
2.9
3.3
Timer stroke with S/T OFF
mm
1.1
0.7
1.5
Basic
*
_02
Pump speed
r/min
1000
1000
1000
Timer stroke with S/T ON
mm
3.1
2.8
3.4
Timer stroke with S/T OFF
mm
1.1
0.6
1.6
_03
Pump speed
r/min
1800
1800
1800
Timer stroke with S/T ON
mm
6.8
6.2
7.4
_04
Pump speed
r/min
2400
2400
2400
Timer stroke with S/T ON
mm
8.5
8
9
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.
42
37
47
Control lever angle gamma
deg.
8.7
8.2
9.2
Test data Ex:
0000001801 POTENTIOMETER ADJUSTMENT
Adjustment of the potentiometer
In the following condition, change the installation position of the potentiometer to adjust the output voltage to within the specified values.
Measure the injection quantity at control lever position a (shim thickness = approximately L mm) at N = N1 r/min, determine the voltage using the formula, and adjust the potentiometer.
A:Performance standards
C:Position of the control lever
N:Pump speed
Vo:Output voltage
E:Conversion formula
G:Idle
H:Full speed
K:Applied voltage
X:Injection quantity (cm3/1,000st)
Y:Voltage (V)
M:Connecting diagram for the potentiometer
O:Output
P:Output when (2) and (3) connected.
R:At target value Q1cm3/1,000 st, set voltage at V3 (V).
----------
N1=700r/min a=8.7deg L=5.6+-0.05mm Q1=15.1cm3/1,000st V3=4.46V
----------
N1=700r/min Q1=15.1cm3/1.000st V1=(2.34+-0.75)V V2=9.96++V V3=4.46V K=10V J:V+-0.03=0.06740X+3.4462
----------
N1=700r/min a=8.7deg L=5.6+-0.05mm Q1=15.1cm3/1,000st V3=4.46V
----------
N1=700r/min Q1=15.1cm3/1.000st V1=(2.34+-0.75)V V2=9.96++V V3=4.46V K=10V J:V+-0.03=0.06740X+3.4462
0000001901 CONTROL LEVER ANGLE
Control lever angle measurement
1. Measure dimension L between the end of the lever and the flange face.
2. Measure the lever angle from the pin hole R (plate).
(A) = pump flange face
(B) = lever angle measuring hole
Alpha = a
beta = b
----------
R=61mm L=25.7~29.7mm
----------
R=61mm L=25.7~29.7mm a=23~27deg b=37~47deg
----------
R=61mm L=25.7~29.7mm
----------
R=61mm L=25.7~29.7mm a=23~27deg b=37~47deg
0000002001 W-CSD ADJUSTMENT
Adjustment of the W-CSD
1. Adjustment of the advance angle of the timer
(1)Determine the timer advance angle from the graph in Fig. 3 (Q).
(2)(1) Adjust using the screw (I) so that the timer advance angle determined in item (1) is obtained.
2. Setting the intermediate lever position (refer to fig 1 and fig 2)
(1)Insert a block gauge L1 between the idling set screw (H) and the control lever (G).
(2)Insert a shim of thickness L2 mm between the intermediate lever (D) and the intermediate lever bracket (E). Ensure the screw (F) contacts the control lever (G), then fix the nut.
3. W-CSD lever adjustment [refer to fig 1 (O) and fig 2 (P)]
(1)After completing (2) above, remove the block gauge L3 and the shim with the thickness L4.
(2)Insert a block gauge L5 determined from the graph (L-theta) in figure 3 (Q) between the idling set screw (H) and the control lever (G).
(3)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 X (V)
Y1:Timer stroke TA (mm)
Y2:Control lever L dimension (mm; control lever position)
J:Graph TA-X:
X (deg C) <= 10: TA = 0.82
10 <= X (deg C) <= 20: TA =-0.027X + 1.09
20 <= X (deg C) < = 40 :TA =-0.0275X + 1.1
K:Graph L-X:
X (deg C) <= 10: L = 3.9
10 <= X (deg C) <= 30: L = -0.09X + 4.8
20 <= X (deg C) <= 54.3: L =-0.086X + 4.68
----------
L1=L=3.0+-0.05mm L2=5.3+-0.05mm L3=3mm L4=5.3mm L5=L+-0.05mm a=30degC
----------
L4=5.3mm
----------
L1=L=3.0+-0.05mm L2=5.3+-0.05mm L3=3mm L4=5.3mm L5=L+-0.05mm a=30degC
----------
L4=5.3mm
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104740-2393
INJECTION-PUMP ASSEMBLY