104741-3310 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047413310

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104741-3310 1047413310

Cross reference number

ZEXEL 104741-3310 1047413310

Zexel num

Bosch num

Firm num

Name

104741-3310

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 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

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 5.5 5.5

Control lever angle alpha deg. 59 55 63

Control lever angle beta deg. 39 34 44

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Adjusting method (service voltage Vi, dummy bolt): 1. Hold the dummy bolt against the control lever when N = N1 r/min, Q = Q1 mm3/st. Fix using the lock nut. 2. When adjusting the potentiometer, position the control lever against the dummy bolt and adjust the potentiometer so that the output voltage is V1 (V). 3. Remove the dummy bolt after the completion of adjustment. Confirm that the potentiometer output voltage is within the standards mentioned when the control lever is idling and in full-speed position. Vi:Applied voltage C:Position of the control lever N:Pump speed (r/min) V:Output voltage (V) Q:Injection quantity (mm3/st) A:Adjusting point B:Checking point C1:Idling C2:Full speed P1:Boost pressure P2:Boost pressure
----------
N1=750r/min Q1=36.4+-1cm3/1,000st V1=5.35+-0.03V Vi=10V
----------
N1=750r/min V1=5.35+-0.03V V2=1.94+-0.52V V3=8.58+-0.76V Q1=36.4+-1.0mm3/st Vi=10V

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the advance angle of the timer (1)Determine the timer advance angle using the following graph. (2)(1) Adjust with the screw (A) so that the timer advance angle determined in the item (1) is obtained. X:Temperature t (deg C) Y:Timer stroke TA (mm) (B): Timer stroke TA (mm):
----------

----------
(C)=TA=-0.04t+2.2(0<=t)

0000002001 W-FICD LEVER ADJUSTMENT

2. Adjustment of the W-FICD (1)Insert a block gauge L 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. G = control lever L dimension (control lever position) H = temperature t (deg C)
----------
L=L+-0.3mm T=3.4~4.9N-m(0.35~0.5kgf-m) a=35degC
----------
L=-0.141t+4.6(0<=t)

0000002101 V-FICD ADJUSTMENT

Adjustment of the two stage actuator (FICD). 1. Install the 2-stage actuator on the injection pump. 2. With the control lever in the idle position adjust using the rod position adjusting nut so that the clearance between control lever and the rod is L1. Note: Actuator stroke adjustment is not necessary. (C) Rod position adjusting nut (D) Stroke adjusting nut (E) Actuator stroke
----------
L1=1+1mm
----------
L1=1+1mm SW1=SW7 SW2=SW8 T1=1.4~2.0N-m(0.14~0.2kgf-m) T2=3.4~4.9N-m(0.35~0.5kgf-m) a=20deg b=20deg