104740-2280 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047402280

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104740-2280 1047402280

Cross reference number

ZEXEL 104740-2280 1047402280

Zexel num

Bosch num

Firm num

Name

104740-2280

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 1400 1400 1400

Average injection quantity mm3/st. 31 30.6 31.4

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 30.4 28.4 32.4

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 29.3 27.3 31.3

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 32 31 33

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 30.8 28.8 32.8

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 2400 2400 2400

Average injection quantity mm3/st. 30.8 28.8 32.8

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 14.8 12.8 16.8

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

Average injection quantity mm3/st. 14.8 11.3 18.3

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2900 2900 2900

Average injection quantity mm3/st. 6

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 9.6 8.6 10.6

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 9.6 7.6 11.6

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 3

Oil temperature degC 50 48 52

Boost compensator adjustment

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 13.5 7 20

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 7 7 7

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 7 7 7

Remarks
MEASURE

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 55 75

Basic *

Oil temperature degC 48 46 50

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 55 75

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 350 350 350

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

Overflow quantity with S/T ON cm3/min 440 310 570

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1000 1000 1000

Pressure with S/T ON kPa 412 383 441

Pressure with S/T ON kgf/cm2 4.2 3.9 4.5

Pressure with S/T OFF kPa 353 304 402

Pressure with S/T OFF kgf/cm2 3.6 3.1 4.1

Basic *

Oil temperature degC 50 48 52

Remarks
ON

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Pressure kPa 412 373 451

Pressure kgf/cm2 4.2 3.8 4.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1400 1400 1400

Pressure kPa 510 471 549

Pressure kgf/cm2 5.2 4.8 5.6

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2400 2400 2400

Pressure kPa 735.5 696 775

Pressure kgf/cm2 7.5 7.1 7.9

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1000 1000 1000

Timer stroke with S/T ON mm 4.4 4.2 4.6

Timer stroke with S/T OFF mm 3.2 2.8 3.6

Basic *

Oil temperature degC 50 48 52

Remarks
ON

_02

Pump speed r/min 1000 1000 1000

Timer stroke mm 4.4 4.1 4.7

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1400 1400 1400

Timer stroke mm 6.4 5.9 6.9

Oil temperature degC 50 48 52

_04

Pump speed r/min 2400 2400 2400

Timer stroke mm 10.65 10.2 11.1

Oil temperature degC 50 48 52

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. 44 39 49

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Adjusting method (dummy bolt method): 1. Adjust at boost pressure P = P1 {P2}. 2. Position the control lever at the adjusting point in the table, hold the dummy bolt against the lever and then fix. 3. Install the potentiometer so that the output voltage is V3 (applied voltage Vi) at the fixed point. 4. After completing potentiometer installation, remove the dummy bolt. 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:Adjustment conditions B:Adjustment value C:Position of the control lever N:Pump speed Q:Injection quantity Vo:Output voltage E:Conversion formula F:Adjusting point G:Idle H:Full speed K:Applied voltage X:Injection quantity (cm3/1,000st) Y:Voltage (V)
----------
N1=700r/min a=11deg L=7.0mm
----------
V1=Measure V2=Measure J:7.5<=X<=11.5cm3/1000st V+-0.03=0.01346X+2.634 11.5<=X<=19.5cm3/1000st V+-0.03=0.0977X+3.059 K=10V

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Setting the intermediate lever position (Refer to Fig. 1(O), 2(P).) (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. 2. Adjustment of the W-CSD lever (Refer to Fig. 1(O), 2(P).) (1)Insert a block gauge L3 determined from the graph (L-t) in figure 3 (Q) between the idling set screw (H) and the control lever (G). (2)Adjust screw B until the W-CSD lever C's roller contacts the intermediate lever D. Then, fix using locknut A. Note: The temperature of the wax at adjustment must not exceed a. X:Temperature t Y:Control lever L dimension (control lever position) J:Graph L-t
----------
L1=L=3.0+-0.05mm L2=5.3+-0.05mm L3=L+-0.05mm a=30degC
----------
L1=3.0+-0.05mm L2=5.3mm J=t(degC)??10?FL=3.9 10??t(degC)??30:L=-0.09t+4.8 30??t(degC)??54.3:L=-0.086t+4.68

0000002001 DASHPOT ADJUSTMENT

Adjustment of the dash pot 1. Insert a block gauge L (thickness gauge) between the idle set screw (C) and the control lever (D). 2. In the above condition, adjust the position of the dash pot so that the dash pot adjustment screw (A) contacts the push rod and then fix the screw using the nut (B). T3T3 Note: (1)The adjusting screw and pushrod contact faces must be smooth. (2)Confirm that the control lever returns to the idling position. (E): 2 locations
----------
T3=4.9~7N-m(0.5~0.7kgf-m) L=6.0+-0.05mm
----------
T1=15.0~20.0N-m{1.5~2.0kgf-m} T2=6.0~9.0N-m{0.6~0.9kgf-m} SW1=22mm SW2=10mm L=6.0+-0.05mm