104701-2003 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047012003

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104701-2003 1047012003

Cross reference number

ZEXEL 104701-2003 1047012003

Zexel num

Bosch num

Firm num

Name

104701-2003

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)
Right R

Governor adjustment

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 617.5 588 647

Pump chamber pressure kgf/cm2 6.3 6 6.6

Basic *

Governor adjustment_02

Pump speed r/min 100 100 100

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 294 294

Pump chamber pressure kgf/cm2 3 3

Governor adjustment_03

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 618 579 657

Pump chamber pressure kgf/cm2 6.3 5.9 6.7

Governor adjustment_04

Pump speed r/min 2000 2000 2000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 755 706 804

Pump chamber pressure kgf/cm2 7.7 7.2 8.2

Boost compensator adjustment

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 70 70 70

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 4.1 3.9 4.3

Basic *

Boost compensator adjustment_02

Pump speed r/min 500 500 500

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 7.4 5.4 9.4

Boost compensator adjustment_03

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 8.1 6.1 10.1

Boost compensator adjustment_04

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 70 70 70

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 4.1 3.8 4.4

Boost compensator adjustment_05

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 0 0 0

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 0 0 0

Boost compensator adjustment_06

Pump speed r/min 1500 1500 1500

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 9.75 9.3 10.2

Speed control lever angle

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Overflow quantity cm3/min 600 470 730

0000000901

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 2.8 2.8 2.8

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 80.5 80 81

Difference in delivery mm3/st. 5

Basic *

_02

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 1.89 1.89 1.89

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 7 4 10

Difference in delivery mm3/st. 2

Basic *

Remarks
Confirmation of difference in delivery

_03

Pump speed r/min 2500 2500 2500

U alpha soll + dU alpha soll V 1.66 1.66 1.66

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 16.1 13.6 18.6

Difference in delivery mm3/st. 5

Basic *

Remarks
Confirmation of difference in delivery

_04

Pump speed r/min 100 100 100

U alpha soll + dU alpha soll V 3.5 3.5 3.5

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 83.3 73.3 93.3

_05

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 1.89 1.89 1.89

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 7 4 10

_06

Pump speed r/min 500 500 500

U alpha soll + dU alpha soll V 2.49 2.49 2.49

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 50.1 48.1 52.1

_07

Pump speed r/min 800 800 800

U alpha soll + dU alpha soll V 1.86 1.86 1.86

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 15.4 13.4 17.4

_08

Pump speed r/min 800 800 800

U alpha soll + dU alpha soll V 2.62 2.62 2.62

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 64.4 62.4 66.4

_09

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 1.85 1.85 1.85

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 16.6 14.6 18.6

_10

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 2.8 2.8 2.8

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 80.5 79.5 81.5

_11

Pump speed r/min 2000 2000 2000

U alpha soll + dU alpha soll V 2.58 2.58 2.58

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 63.7 61.7 65.7

_12

Pump speed r/min 2250 2250 2250

U alpha soll + dU alpha soll V 2.43 2.43 2.43

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 54.3 51.8 56.8

_13

Pump speed r/min 2500 2500 2500

U alpha soll + dU alpha soll V 1.66 1.66 1.66

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 16.1 13.6 18.6

_14

Pump speed r/min 2500 2500 2500

U alpha soll + dU alpha soll V 1 1 1

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 3

Stop lever angle

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 1.89 1.89 1.89

TCV duty (%) F TCV 60Hz % 0 0 0

Average injection quantity cm3/min 0 0 0

Stop lever angle_02

Pump speed r/min 2250 2250 2250

U alpha soll + dU alpha soll V 2.43 2.43 2.43

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity cm3/min 0 0 0

0000001101

Pump speed r/min 200 200 200

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.7 2.7 2.7

Speed output
N=Measure the actual speed. r/min N+-8

0000001201

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 100 100 100

U alpha soll V 2.8 2.8 2.8

Temperature output
Measure T = actual output temperature degC T+-5

0000001301

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.62 5.52 5.72

Pre-stroke mm 0.1 0.08 0.12

Test data Ex:

Injection timing adjustment Comp. resistor/voltage

Compensation resistance/compensation voltage comparison A = Compensation resistor number B= Compensation resistance C = Compensation voltage delta U alpha soll
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0000001601 HARNESS & CONNECTOR

Corrugated tube assembly specification (1)Maintain the corrugated tube so that the dimension of the end of the connector and the end of the corrugated are as shown in the figure. (2)At K, pull the Q adjustment resistor towards the clip. (3)Wrap black vinyl tape 4 times around the end of the corrugated tube to fix the tube. A:RS03M-GY B:RS08M-GY C:RS08M-B D:Q adjustment resistor E:Corrugated tube J:PVC tape
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L1=50+-10mm L2=40+-10mm L3=50+-10mm

0000001701 HARNESS & CONNECTOR

Injection quantity adjustment compensation resistor assembly standards (1)Fix the injection quantity adjustment compensation resistor (Q adjustment resistor) using clips. (2)After fixing the corrugated tube, and with the corrugated tube's end and the end of the Q adjustment resistor aligned, fix the Q adjustment resistor so that it is positioned in the direction shown by the arrow in the figure (each connector clip side). (3)Fix the Q adjustment harness's protective tube to the corrugated tube using black PVC tape. (4)After confirming that the Q adjustment resistor is fixed in the position as shown by the arrow in diagram, cut off the excess clip to leave L2. A:End of corrugated tube B:Injection quantity adjustment compensation resistor (Q adjustment resistor) C:After attaching the clip to the Q adjustment resistor, fix the corrugated tube. D:Q adjustment resistor harness protective tube E:PVC tape K:Figure shown by arrow
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L1=(90mm) L2=(10mm)