104740-2460 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047402460

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104740-2460 1047402460

Cross reference number

ZEXEL 104740-2460 1047402460

Zexel num

Bosch num

Firm num

Name

104740-2460

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105000-2010

Bosch type code NP-DN12SD12TT

Nozzle holder 105780-2080

Opening pressure MPa 14.7 14.7 15.19

Opening pressure kgf/cm2 150 150 155

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840

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. 30.2 29.7 30.7

Difference in delivery mm3/st. 2

Basic *

Remarks
Full

Injection timing adjustment_02

Pump speed r/min 900 900 900

Boost pressure kPa 35.35 34 36.7

Boost pressure mmHg 265 255 275

Average injection quantity mm3/st. 40 39.5 40.5

Difference in delivery mm3/st. 2

Basic *

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 2700 2700 2700

Boost pressure kPa 64.55 63.2 65.9

Boost pressure mmHg 484 474 494

Average injection quantity mm3/st. 8.7 5.2 12.2

Injection timing adjustment_04

Pump speed r/min 2200 2200 2200

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 36.8 34.8 38.8

Injection timing adjustment_05

Pump speed r/min 900 900 900

Boost pressure kPa 35.35 34 36.7

Boost pressure mmHg 265 255 275

Average injection quantity mm3/st. 40 39 41

Injection timing adjustment_06

Pump speed r/min 600 600 600

Boost pressure kPa 8

Boost pressure mmHg 60

Average injection quantity mm3/st. 30.2 29.2 31.2

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Boost pressure kPa 64.55 63.2 65.9

Boost pressure mmHg 484 474 494

Average injection quantity mm3/st. 9.7 6.7 12.7

Difference in delivery mm3/st. 4.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Boost pressure kPa 64.55 63.2 65.9

Boost pressure mmHg 484 474 494

Average injection quantity mm3/st. 6

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 *

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 5.5 7.5

Governor adjustment_03

Pump speed r/min 500 500 500

Boost pressure kPa 8

Boost pressure mmHg 60

Average injection quantity mm3/st. 3

Boost compensator adjustment

Pump speed r/min 900 900 900

Boost pressure kPa 35.35 34 36.7

Boost pressure mmHg 265 255 275

Average injection quantity mm3/st. 7 2 12

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 *

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

Remarks
Magnet OFF

0000000901

Pump speed r/min 900 900 900

Overflow quantity cm3/min 381 246 516

Stop lever angle

Pump speed r/min 900 900 900

Boost pressure kPa 35.35 34 36.7

Boost pressure mmHg 265 255 275

Pressure kPa 343.5 314 373

Pressure kgf/cm2 3.5 3.2 3.8

Basic *

Stop lever angle_02

Pump speed r/min 900 900 900

Boost pressure kPa 35.35 34 36.7

Boost pressure mmHg 265 255 275

Pressure kPa 343 304 382

Pressure kgf/cm2 3.5 3.1 3.9

Stop lever angle_03

Pump speed r/min 1200 1200 1200

Boost pressure kPa 35.35 34 36.7

Boost pressure mmHg 265 255 275

Pressure kPa 412 373 451

Pressure kgf/cm2 4.2 3.8 4.6

Stop lever angle_04

Pump speed r/min 2400 2400 2400

Boost pressure kPa 35.35 34 36.7

Boost pressure mmHg 265 255 275

Pressure kPa 716 677 755

Pressure kgf/cm2 7.3 6.9 7.7

0000001101

Pump speed r/min 900 900 900

Boost pressure kPa 35.35 34 36.7

Boost pressure mmHg 265 255 275

Timer stroke mm 1.2 1 1.4

Basic *

_02

Pump speed r/min 900 900 900

Boost pressure kPa 35.35 34 36.7

Boost pressure mmHg 265 255 275

Timer stroke mm 1.5 1.2 1.8

_03

Pump speed r/min 1200 1200 1200

Boost pressure kPa 35.35 34 36.7

Boost pressure mmHg 265 255 275

Timer stroke mm 3.2 2.7 3.7

_04

Pump speed r/min 2400 2400 2400

Boost pressure kPa 35.35 34 36.7

Boost pressure mmHg 265 255 275

Timer stroke 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 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

Control lever angle gamma deg. 7 6.5 7.5

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer * Measure the injection quantity at N = N1r/min with the control lever position C3 (equivalent to L1 mm). Determine the voltage with the conversion formula and adjust the potentiometer. Voltage conversion formula: V+-0.03 = xQ + y (V) A:Performance standards for the potentiometer B:Conversion point C:Position of the control lever D:Lever opening (from idle) E:Standards for the potentiometer's ON/OFF switch Vi:Applied voltage V:Potentiometer voltage X:Injection quantity: Q Y:Voltage N1:Pump speed C3:Position of the control lever L1:Thickness of the shim C1:Idle C2:Full-speed B1:ON-->OFF B2:OFF-->ON F:Connecting diagram for the potentiometer G:Output when (2) and (3) connected. H:When (4) or (6) connected: switch OFF to ON. I:When (4) or (5) connected: switch ON to OFF. J:Output
----------
x=0.073 y=1.727 N1=600r/min C3=7deg L1=4.6mm Vi=10V
----------
V1=Above 0.2V V2=Below 9.6V Vi=10V D1=5+-3deg D2=Above 21.5deg

0000001901 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 idle position. (2)Insert a block gauge (thickness gauge) L1 between the intermediate lever D and the intermediate lever bracket K and fix intermediate lever D. (3)At this time, adjust screw (A) so that it is horizontal and the clearance between screw (A) and the control lever (C) is L2. Then, fix using nut (B). 2. Fixing the M-CSD stopper (I) (1)At roller holder advance angle '0' adjust the lever shaft ball pin so that it contacts the roller holder. (2)At this time, fix the stopper I using the screw J where the distance a between the CSD lever F and the stopper is L3. (3)Pull the CSD lever F in the direction X until it contacts the stopper I and confirm that the timer stroke is L4. 3. Screw G adjustment (without a block gauge L3 at a) (1)Adjust screw G so that the distance between screw A adjusted above in 1 and the control lever is above L5, then fix using nut H. (2)Confirm that the control lever shim thickness is L6. (M) = shim thickness L = dimension L
----------
L1=1.5mm L2=1mm L3=Approx. 4.5mm L4=1.23+-0.2mm L5=Above1mm L6=7.2+-0.5mm
----------
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=1.5mm L3=Approx. 4.5mm L5=Above 1mm L6=7.2+-0.5mm