104741-3300 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047413300

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104741-3300 1047413300

Cross reference number

ZEXEL 104741-3300 1047413300

Zexel num

Bosch num

Firm num

Name

104741-3300

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

(Solenoid timer adjustment condition)
With S/T O-ring; S/T OFF. OFF

Injection timing adjustment

Pump speed r/min 600 600 600

Boost pressure kPa 31.3 30 32.6

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 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 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 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 mmHg 0 0 0

Average injection quantity mm3/st. 57.2 56.2 58.2

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

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 mmHg 550 540 560

Average injection quantity mm3/st. 75.8 72.3 79.3

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 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 mmHg 550 540 560

Average injection quantity mm3/st. 12

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 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 400 400 400

Boost pressure kPa 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 400 400 400

Boost pressure kPa 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

Governor adjustment_03

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5

Oil temperature degC 50 48 52

Boost compensator adjustment

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 36.4 34.9 37.9

Oil temperature degC 50 48 52

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. 112 97 127

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 110 90 130

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 400 400 400

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 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Overflow quantity with S/T ON 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 mmHg 550 540 560

Pressure with S/T ON kPa 559 520 598

Pressure with S/T ON kgf/cm2 5.7 5.3 6.1

Pressure with S/T OFF kPa 510 490 530

Pressure with S/T OFF kgf/cm2 5.2 5 5.4

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_02

Pump speed r/min 700 700 700

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T OFF kPa 373 324 422

Pressure with S/T OFF kgf/cm2 3.8 3.3 4.3

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 mmHg 550 540 560

Pressure with S/T ON kPa 559 520 598

Pressure with S/T ON kgf/cm2 5.7 5.2 6.2

Pressure with S/T OFF kPa 510 481 539

Pressure with S/T OFF kgf/cm2 5.2 4.9 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_04

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T OFF kPa 667 618 716

Pressure with S/T OFF kgf/cm2 6.8 6.3 7.3

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T ON mm 6.6 6.1 7.1

Timer stroke with S/T OFF mm 5.5 5.3 5.7

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 700 700 700

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T ON mm 3.3 2.6 4

Timer stroke with S/T OFF mm 1.9 1.1 2.7

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T ON mm 6.6 5.9 7.3

Timer stroke with S/T OFF mm 5.5 5.1 5.9

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T OFF mm 6.8 6.2 7.4

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T OFF mm 9.4 8.6 10.2

Oil temperature degC 50 48 52

_06

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T OFF mm 9.8 9.3 10.2

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 6.01 5.91 6.11

MS dimension mm 0.7 0.6 0.8

BCS stroke mm 5.5 5.3 5.7

Control lever angle alpha deg. 59 55 63

Control lever angle beta deg. 39 34 44

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)
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SW=10mm T=6~9N-m(0.6~0.9kgf-m)

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Dummy bolt method 1. Hold the dummy bolt against the control lever at position N = N1 and Q = Q1 and fix using the lock nut. 2. At potentiometer adjustment, with the control lever contacting the dummy bolt, adjust the potentiometer so that the output voltage is V1. 3. After adjustment, remove the dummy bolt and confirm that the potentiometer output voltage at the control lever's idling and full speed positions is as specified above. N:Pump speed Q:Injection quantity V:Output voltage A:Adjusting point B:Checking point C:Position of the control lever C1:Idling C2:Full speed Vi:Applied voltage
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N1=750r/min Q1=36.4+-1mm3/st V1=5.35+-0.03V Vi=10V
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N1=750r/min Q1=36.4+-1mm3/st V1=5.35+-0.03V V2=1.94+-0.52V V3=8.58+-0.76V Vi=10V

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD Adjustment of the timer advance angle Adjust screw (A) so that the timer stroke is the value determined from the graph (B). (C): Timer stroke TA (mm) X:Temperature t (deg C) Y:Timer stroke TA (mm)
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(C)=TA=-0.04t+2.2(0<=t)

0000002001 W-FICD LEVER ADJUSTMENT

W-FICD adjustment (1)Insert a block gauge L1 determined from the graph between the control lever (B) and the idling set screw (A). (2)Fix bolt (E) in the position where W-FICD lever (C) contacts the control lever (D). (Tighten to torque T.) (3)Remove the block gauge and shims after completing adjustment. Caution: The temperature of the wax at adjustment must not exceed a. Y = control lever dimension L (control lever position) X = temperature t (deg C)
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L1=L+-0.3mm T=3.4~4.9N-m(0.35~0.5kgf-m) a=35degC
----------