104741-3891 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047413891


104741-3891 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 104741-3891 1047413891

Cross reference number

ZEXEL 104741-3891 1047413891


Zexel num
Bosch num
Firm num
Name
104741-3891 
 
   
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   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.   58.5 58 59
Difference in delivery mm3/st.   4.5
Basic   *
Oil temperature degC   50 48 52
Remarks
NA
 
Injection timing adjustment_02
Pump speed r/min   750 750 750
Boost pressure kPa   53.3 52 54.6
Boost pressure kgf/cm2   0.54 0.526 0.554
Boost pressure mmHg   400 390 410
Average injection quantity mm3/st.   71.5 71 72
Difference in delivery mm3/st.   5.5
Basic   *
Oil temperature degC   50 48 52
Remarks
CBS
 
Injection timing adjustment_03
Pump speed r/min   1000 1000 1000
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Average injection quantity mm3/st.   83.1 82.6 83.6
Difference in delivery mm3/st.   6.5
Basic   *
Oil temperature degC   50 48 52
Remarks
Full
 
Injection timing adjustment_04
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.   58.5 57.5 59.5
Basic   *
Oil temperature degC   50 48 52
Remarks
NA
 
Injection timing adjustment_05
Pump speed r/min   750 750 750
Boost pressure kPa   53.3 52 54.6
Boost pressure kgf/cm2   0.54 0.526 0.554
Boost pressure mmHg   400 390 410
Average injection quantity mm3/st.   71.5 70.5 72.5
Basic   *
Oil temperature degC   50 48 52
Remarks
CBS
 
Injection timing adjustment_06
Pump speed r/min   1000 1000 1000
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Average injection quantity mm3/st.   83.1 82.1 84.1
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   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Average injection quantity mm3/st.   71 67 75
Oil temperature degC   50 48 52
Injection quantity adjustment
Pump speed r/min   2475 2475 2475
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Average injection quantity mm3/st.   26.4 23.4 29.4
Difference in delivery mm3/st.   8
Basic   *
Oil temperature degC   55 52 58
Injection quantity adjustment_02
Pump speed r/min   3000 3000 3000
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Average injection quantity mm3/st.   8
Oil temperature degC   55 52 58
Injection quantity adjustment_03
Pump speed r/min   2475 2475 2475
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Average injection quantity mm3/st.   26.4 21.4 31.4
Difference in delivery mm3/st.   8.5
Basic   *
Oil temperature degC   55 52 58
Governor adjustment
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure kgf/cm2   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   18.9 16.9 20.9
Difference in delivery mm3/st.   2
Basic   *
Oil temperature degC   48 46 50
Governor adjustment_02
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure kgf/cm2   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   18.9 16.4 21.4
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 kgf/cm2   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   5
Oil temperature degC   50 48 52
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.   78.1 58.1 98.1
Basic   *
Oil temperature degC   48 46 50
Remarks
Full
 
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.   78.1 58.1 98.1
Oil temperature degC   48 46 50
Remarks
Full
 
Speed control lever angle
Pump speed r/min   375 375 375
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   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Overflow quantity with S/T ON cm3/min   740 610 870
Oil temperature degC   50 48 52
Stop lever angle
Pump speed r/min   1500 1500 1500
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Pressure with S/T ON kPa   647 608 686
Pressure with S/T ON kgf/cm2   6.6 6.2 7
Pressure with S/T OFF kPa   500 480 520
Pressure with S/T OFF kgf/cm2   5.1 4.9 5.3
Basic   *
Oil temperature degC   50 48 52
Remarks
OFF
 
0000001101
Pump speed r/min   1500 1500 1500
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Timer stroke with S/T ON mm   6.8 6.3 7.3
Timer stroke with S/T OFF mm   3.4 3.2 3.6
Basic   *
Oil temperature degC   50 48 52
Remarks
OFF
 
_02
Pump speed r/min   1000 1000 1000
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Timer stroke with S/T ON mm   3.9 3.2 4.6
Timer stroke with S/T OFF mm   1
Oil temperature degC   50 48 52
_03
Pump speed r/min   1250 1250 1250
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Timer stroke with S/T OFF mm   2 1.3 2.7
Oil temperature degC   50 48 52
_04
Pump speed r/min   1500 1500 1500
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Timer stroke with S/T ON mm   6.8 6.1 7.5
Timer stroke with S/T OFF mm   3.4 3 3.8
Basic   *
Oil temperature degC   50 48 52
Remarks
OFF
 
_05
Pump speed r/min   2000 2000 2000
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Timer stroke with S/T OFF mm   6.3 5.6 7
Oil temperature degC   50 48 52
_06
Pump speed r/min   2300 2300 2300
Boost pressure kPa   86.6 85.3 87.9
Boost pressure kgf/cm2   0.88 0.866 0.894
Boost pressure mmHg   650 640 660
Timer stroke with S/T ON mm   8.6 8.1 9
Timer stroke with S/T OFF mm   8 7.3 8.7
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   5.8 5.7 5.9
MS dimension mm   0.9 0.8 1
BCS stroke mm   5.1 4.9 5.3
Control lever angle alpha deg.   59 55 63
Control lever angle beta deg.   42 37 47

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Test data 104741-3891
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 V1=5.10+-0.03V Q1=34.7+-1.0cm3/1,000st
----------
N1=750r/min V1=5.10+-0.03V V2=2.16+-0.52V V3=9.02+-0.72V Q1=34.7+-1.0cm3/1,000st Vi=10V P1=-kPa P2=-mmHg

0000001901 W-CSD ADJUSTMENT

Test data 104741-3891
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):
----------

----------
(B)=TA=-0.04t+1.2(0<=t<=30)

0000002001 W-FICD LEVER ADJUSTMENT

Test data 104741-3891
2. Adjustment of the W-FICD (1)Insert a block gauge L1 determined from the graph below between the control lever (D) and the idle set screw (C). (2)Tighten the nut (F) at the position where the W-FICD lever (E) the control lever (D) contact. T2T2 (3)After adjusting the W-FICD lever (E), confirm that the timer stroke is the value adjusted in item 1. Then, remove the shim. Y = control lever position X = temperature G = control lever position: (mm)
----------
L1=L+-0.3 mm T2=6~9 Nm{0.6~0.9 kgf}
----------
L1=L+-0.3 mm SW2=SW10 T2=6~9 Nm{0.6~0.9 kgfm} SW1=SW8 T1=3.4~4.9 Nm{0.35~0.5 kgfm}




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