104741-3901 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047413901

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Information injection-pump assembly

ZEXEL 104741-3901 1047413901

Cross reference number

ZEXEL 104741-3901 1047413901

Zexel num

Bosch num

Firm num

Name

104741-3901

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. 48.6 48.1 49.1

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 46.7 45.4 48

Boost pressure kgf/cm2 0.48 0.466 0.494

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 67.7 67.2 68.2

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. 48.6 47.6 49.6

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 750 750 750

Boost pressure kPa 46.7 45.4 48

Boost pressure kgf/cm2 0.48 0.466 0.494

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 67.7 66.7 68.7

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 400 400 400

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 400 400 400

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 100 100 100

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 91.7 71.7 111.7

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 kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 91.7 71.7 111.7

Oil temperature degC 48 46 50

Remarks
IDLE

Speed control lever angle

Pump speed r/min 400 400 400

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 670 540 800

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 5.2 8

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 0.6 0.5 0.7

BCS stroke mm 6.8 6.6 7

Control lever angle alpha deg. 59 55 63

Control lever angle beta deg. 42 37 47

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 V1=4.26+-0.03V Q1=34.7+-1.0cm3/1,000st Vi=10V
----------
N1=750r/min V1=4.26+-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

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

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}