104740-2393 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047402393


104740-2393 INJECTION-PUMP ASSEMBLY
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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
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)
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
 
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
 
Timer adjustment
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   60 50 70
Basic   *
Remarks
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
 
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

Test data 104740-2393
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

0000001901 CONTROL LEVER ANGLE

Test data 104740-2393
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

0000002001 W-CSD ADJUSTMENT

Test data 104740-2393
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




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