104741-3140 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047413140

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Information injection-pump assembly

ZEXEL 104741-3140 1047413140

Cross reference number

ZEXEL 104741-3140 1047413140

Zexel num

Bosch num

Firm num

Name

104741-3140

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 31.3 30 32.6

Boost pressure kgf/cm2 0.32 0.306 0.334

Boost pressure mmHg 235 225 245

Average injection quantity mm3/st. 67.3 66.8 67.8

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

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. 57.2 56.7 57.7

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 81.3 80.8 81.8

Difference in delivery mm3/st. 6.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 600 600 600

Boost pressure kPa 31.3 30 32.6

Boost pressure kgf/cm2 0.32 0.306 0.334

Boost pressure mmHg 235 225 245

Average injection quantity mm3/st. 67.3 66.3 68.3

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_05

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. 57.2 56.2 58.2

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 81.3 80.3 82.3

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 74.4 70.4 78.4

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 56.8 53.8 59.8

Difference in delivery mm3/st. 17

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 3000 3000 3000

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 7

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 56.8 51.8 61.8

Difference in delivery mm3/st. 17.5

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 365 365 365

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12.4 10.4 14.4

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 365 365 365

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12.4 9.9 14.9

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Boost compensator 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. 30.7 30.7 30.7

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 21.2 21.2 21.2

Timer adjustment

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. 52 42 62

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

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. 52 42 62

Oil temperature degC 48 46 50

Remarks
IDLE

Speed control lever angle

Pump speed r/min 365 365 365

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 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Overflow quantity cm3/min 740 610 870

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Pressure kPa 559 539 579

Pressure kgf/cm2 5.7 5.5 5.9

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 700 700 700

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Pressure kPa 422 373 471

Pressure kgf/cm2 4.3 3.8 4.8

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Pressure kPa 559 530 588

Pressure kgf/cm2 5.7 5.4 6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Pressure kPa 608 559 657

Pressure kgf/cm2 6.2 5.7 6.7

Oil temperature degC 50 48 52

Stop lever angle_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Pressure kPa 716 667 765

Pressure kgf/cm2 7.3 6.8 7.8

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Timer stroke mm 6.7 6.5 6.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 700 700 700

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Timer stroke mm 3.3 2.7 3.9

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Timer stroke mm 6.7 6.3 7.1

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure kgf/cm2 0.75 0.736 0.764

Boost pressure mmHg 550 540 560

Timer stroke mm 9.8 9.3 10.2

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 6.01 5.91 6.11

MS dimension mm 0.7 0.6 0.8

BCS stroke mm 5 4.8 5.2

Control lever angle alpha deg. 59 55 63

Control lever angle beta deg. 42 37 47

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.
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N1=600r/min N2=750r/min P1=31.3kPa(235mmHg) 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:Applied voltage C:Position of the control lever N:Pump speed V:Output voltage Q:Injection quantity A:Adjusting point C1:Idling C2:Full speed
----------

----------
V1=1.6+-0.03V V2=(8.63+-1.5V) Vi=10V

0000001901 ACCELERATOR LINK STROKE

Adjustment of the accelerator link stroke As shown in the figure, adjust so that the accelerator link's stroke between idle (B) and full speed (A) is L1. (A): Full-speed (B): Idle
----------
L=32.9+-1mm
----------
L=32.9+-1mm