104740-0690 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047400690

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Information injection-pump assembly

ZEXEL 104740-0690 1047400690

Cross reference number

ZEXEL 104740-0690 1047400690

Zexel num

Bosch num

Firm num

Name

104740-0690

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

Injection timing adjustment

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 49.8 49.3 50.3

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 750 750 750

Boost pressure kPa 40 38.7 41.3

Boost pressure kgf/cm2 0.41 0.396 0.424

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 66.2 65.7 66.7

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 78.2 77.7 78.7

Difference in delivery mm3/st. 6.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 49.8 48.8 50.8

Difference in delivery mm3/st. 4.5

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 750 750 750

Boost pressure kPa 40 38.7 41.3

Boost pressure kgf/cm2 0.41 0.396 0.424

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 66.2 65.2 67.2

Difference in delivery mm3/st. 6

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 78.2 77.2 79.2

Difference in delivery mm3/st. 7

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 2000 2000 2000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 68.5 65 72

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2450 2450 2450

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 23.5 20.5 26.5

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2450 2450 2450

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 23.5 20 27

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

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

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10.5 9 12

Difference in delivery mm3/st. 2.5

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 70 50 90

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 150 150 150

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 70 50 90

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_03

Pump speed r/min 150 150 150

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 70 50 90

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

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

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Oil temperature degC 50 48 52

Remarks
MEASURE

Stop lever angle

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure kPa 510 481 539

Pressure kgf/cm2 5.2 4.9 5.5

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 500 500 500

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure kPa 392 343 441

Pressure kgf/cm2 4 3.5 4.5

Oil temperature degC 48 46 50

Stop lever angle_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure kPa 510 471 549

Pressure kgf/cm2 5.2 4.8 5.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2000 2000 2000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure kPa 735 686 784

Pressure kgf/cm2 7.5 7 8

Oil temperature degC 50 48 52

Stop lever angle_05

Pump speed r/min 2150 2150 2150

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure kPa 775 726 824

Pressure kgf/cm2 7.9 7.4 8.4

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke mm 4.4 4.2 4.6

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 500 500 500

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke mm 1.8 1 2.6

Oil temperature degC 48 46 50

_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke mm 4.4 4 4.8

Oil temperature degC 50 48 52

_04

Pump speed r/min 2000 2000 2000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke mm 9 8.2 9.8

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 47.8 47.3 48.3

Timer stroke TA mm 3.5 3.3 3.7

Timer stroke variation dT mm 0.9 0.9 0.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 47.8 46.8 48.8

Timer stroke TA mm 3.5 3.1 3.9

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 30 28.5 31.5

Timer stroke TA mm 3 2.4 3.6

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 6.01 5.91 6.11

MS dimension mm 0.9 0.8 1

BCS stroke mm 6.8 6.6 7

Pre-stroke mm 0.05 0.03 0.07

Control lever angle alpha deg. 12.5 8.5 16.5

Control lever angle beta deg. 40 37 43

Test data Ex:

0000001601 BOOST COMPENSATOR ADJUSTMENT

BCS adjustment procedure 1. At full boost pressure, set so that the full injection quantity is within the specifications (adjusting point). 2. Perform boost compensator intermediate operation point adjustment (pump speed N1, boost pressure P1). 3. When injection quantity at boost pressure P2 and pump speed N2 is not as specified, loosen nut (A) and adjust position of screw (B) so that injection quantity is as specified. The screw position should be within +-1 turn of initial position. 4. The nut tightening torque is T.
----------
N1=750r/min N2=750r/min P1=40kPa(300mmHg) P2=0kPa(0mmHg) T=6~9N-m(0.6~0.9kgf-m)
----------
SW=10mm T=6~9N-m(0.6~0.9kgf-m)

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Vi = input applied voltage (1)Potentiometer setting: (A): Adjusting point (B): Checking point (C): Control lever opening (V): P/N output voltage (2)Dummy bolt setting: At pump speed N1, fix the control lever using the dummy bolt to obtain injection quantity Q1 from the graph. (N): Speed of the pump (Q): Injection quantity (D): Targeted lever angle C1:Full speed position C2:Idling position (3)In condition (2) above, read the potentiometer output voltage (V), select a compensation resistor from the table and replace the resistor. (R): Compensation resistance Note As the output voltage is compensated in the control unit after replacing the compensation resistor, confirmation is not necessary.
----------
N1=1000r/min Q1=30.0+-1.0mm3/st Vi=10V
----------
Vi=10V V1=8.4+-0.03V V2=(1.73+-0.7V) N1=1000r/min Q1=30.0+-1.0mm3/st D1=18.0deg V3=3.95~4.06V V4=4.07~4.18V V5=4.19~4.30V V6=4.31~4.42V V7=4.43~4.54V V8=4.55~4.66V V9=4.67~4.78V V10=4.79~4.90V V11=4.91~5.02V V12=5.03~5.14V V13=5.15~5.26V V14=5.27~5.38V V15=5.39~5.51V R1=No.1,0.18kohm R2=No.2,0.30kohm R3=No.3,0.43kohm R4=No.4,0.62kohm R5=No.5,0.82kohm R6=No.6,1.10kohm R7=No.7,1.50kohm R8=No.8,2.00kohm R9=No.9,2.70kohm R10=No.10,3.90kohm R11=No.11,5.60kohm R12=No.12,8.20kohm R13=No.13,15.0kohm

0000001901 WIRE

(1)Confirmation of the wire length: Accelerator wire: Idle-full stroke: L1 (2)Confirmation on the idle SW Confirm that the switch is ON at the idle lever position. (3)Adjustment of the double stage actuator: 1. Apply negative pressure P1 to the actuator through the negative pressure suction inlet. 2. Under the conditions in 1. above, adjust using screw (C) so that the control lever () position is angle a [clearance L2+-0.5mm from idle switch (E)], and fix using the nut (D). (Tightening torque T) b:Angle alpha
----------
L1=34.1+-3.5mm L2=3.8mm P1=-66.6kPa(-500mmHg) a=9deg T=6~9N-m(0.6~0.9kgf-m)
----------
L2=(3.8mm) a=9deg b=12.5+-4deg