104740-2141 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047402141

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104740-2141 1047402141

Cross reference number

ZEXEL 104740-2141 1047402141

Zexel num

Bosch num

Firm num

Name

104740-2141

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

Injection timing adjustment

Pump speed r/min 600 600 600

Boost pressure kPa 8

Boost pressure mmHg 60

Average injection quantity mm3/st. 31 30.6 31.4

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_02

Pump speed r/min 900 900 900

Boost pressure kPa 35.3 34 36.6

Boost pressure mmHg 265 255 275

Average injection quantity mm3/st. 39.1 38.7 39.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 600 600 600

Boost pressure kPa 8

Boost pressure mmHg 60

Average injection quantity mm3/st. 31 30 32

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 900 900 900

Boost pressure kPa 35.3 34 36.6

Boost pressure mmHg 265 255 275

Average injection quantity mm3/st. 39.1 38.1 40.1

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1200 1200 1200

Boost pressure kPa 75.2 73.9 76.5

Boost pressure mmHg 564 554 574

Average injection quantity mm3/st. 47 45 49

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1800 1800 1800

Boost pressure kPa 77.3 76 78.6

Boost pressure mmHg 580 570 590

Average injection quantity mm3/st. 45.1 42.6 47.6

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 2200 2200 2200

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 39.7 36.7 42.7

Oil temperature degC 52 50 54

Injection timing adjustment_08

Pump speed r/min 2400 2400 2400

Boost pressure kPa 64.5 63.2 65.8

Boost pressure mmHg 484 474 494

Average injection quantity mm3/st. 37.3 33.8 40.8

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Boost pressure kPa 64.5 63.2 65.8

Boost pressure mmHg 484 474 494

Average injection quantity mm3/st. 12.7 10.7 14.7

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

Boost pressure kPa 64.5 63.2 65.8

Boost pressure mmHg 484 474 494

Average injection quantity mm3/st. 12.7 9.2 16.2

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2800 2800 2800

Boost pressure kPa 64.5 63.2 65.8

Boost pressure mmHg 484 474 494

Average injection quantity mm3/st. 6

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 400 400 400

Boost pressure kPa 8

Boost pressure mmHg 60

Average injection quantity mm3/st. 6.5 5.5 7.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 400 400 400

Boost pressure kPa 8

Boost pressure mmHg 60

Average injection quantity mm3/st. 6.5 4.5 8.5

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 500 500 500

Boost pressure kPa 8

Boost pressure mmHg 60

Average injection quantity mm3/st. 3

Oil temperature degC 48 46 50

Boost compensator adjustment

Pump speed r/min 600 600 600

Boost pressure kPa 8

Boost pressure mmHg 60

Average injection quantity mm3/st. 13.9 9.4 18.4

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 4.6 4.6 4.6

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Boost pressure kPa 35.3 34 36.6

Boost pressure mmHg 265 255 275

Average injection quantity mm3/st. 7 2 12

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 4.6 4.6 4.6

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 50 40 60

Basic *

Oil temperature degC 48 46 50

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 8

Boost pressure mmHg 60

Average injection quantity mm3/st. 50 40 60

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 325 325 325

Boost pressure kPa 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 900 900 900

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 370 240 500

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 900 900 900

Boost pressure kPa 35.3 34 36.6

Boost pressure mmHg 265 255 275

Pressure kPa 343 314 372

Pressure kgf/cm2 3.5 3.2 3.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 900 900 900

Boost pressure kPa 35.3 34 36.6

Boost pressure mmHg 265 255 275

Pressure kPa 343 304 382

Pressure kgf/cm2 3.5 3.1 3.9

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1200 1200 1200

Boost pressure kPa 75.2 73.9 76.5

Boost pressure mmHg 564 554 574

Pressure kPa 412 373 451

Pressure kgf/cm2 4.2 3.8 4.6

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2400 2400 2400

Boost pressure kPa 64.5 63.2 65.8

Boost pressure mmHg 484 474 494

Pressure kPa 716 677 755

Pressure kgf/cm2 7.3 6.9 7.7

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 900 900 900

Boost pressure kPa 35.3 34 36.6

Boost pressure mmHg 265 255 275

Timer stroke mm 1.5 1.3 1.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Boost pressure kPa 35.3 34 36.6

Boost pressure mmHg 265 255 275

Timer stroke mm 1.5 1.2 1.8

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1200 1200 1200

Boost pressure kPa 75.2 73.9 76.5

Boost pressure mmHg 564 554 574

Timer stroke mm 3.2 2.9 3.5

Oil temperature degC 50 48 52

_04

Pump speed r/min 2400 2400 2400

Boost pressure kPa 64.5 63.2 65.8

Boost pressure mmHg 484 474 494

Timer stroke mm 8.55 8.1 9

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 5.75 5.65 5.85

MS dimension mm 0.9 0.8 1

BCS stroke mm 3.8 3.7 3.9

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 39 34 44

Test data Ex:

0000001801 M-CSD ADJUSTMENT

M-CSD adjustment 1. Fixing intermediate lever screw (A) [roller (E) must not contact intermediate lever (D)] (1)Hold the control lever (C) in the idling position. (2)At this time, adjust screw (A) so that it is horizontal and the clearance between screw (A) and the control lever (C) is L1. Then, fix using nut (B). 2. Fixing the M-CSD stopper (I) Pull the CSD lever (F) in the direction X until it contacts the stopper (I) and tighten the socket head bolt (J) when the timer advance angle is L2. 3. Screw (G) adjustment Pull the CSD lever (F) in the direction X until it contacts the stopper (I) and adjust the screw (G) so that the control lever shim thickness is L3. Then, tighten nut (H).
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L1=1~2mm L2=1.2+-0.2mm L3=7.2+-0.5mm
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T1=6~9N-m(0.6~0.9kgf-m) T2=5~7N-m(0.5~0.7kgf-m) T3=2~3N-m(0.2~0.3kgf-m) L1=1~2mm L3=7.2+-0.5mm

0000001901 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer At pump speed N = N1 and with the control lever angle at a from the idle position (corresponding to a shim thickness of L), convert the injection quantity obtained to a voltage value using the graph and adjust the potentiometer. Caution: Confirm that the voltage increases when the control lever is turned to the full speed side. E:J = formula Vi:Applied voltage Vo = output voltage Q = injection quantity
----------
N1=600(r/min) a=7(deg) L=4.6(mm) E:J=V+-0.05=0.125Q+2.6625
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E:J=V+-0.05=0.125Q+2.6625