104742-1401 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047421401

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104742-1401 1047421401

Cross reference number

ZEXEL 104742-1401 1047421401

Zexel num

Bosch num

Firm num

Name

104742-1401

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 1000 1000 1000

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 46.5 46 47

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 32.3 28.3 36.3

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 600 600 600

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 33 30.5 35.5

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 46.5 45.5 47.5

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1000 1000 1000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 33.5 30.5 36.5

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1400 1400 1400

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 55.2 52.2 58.2

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1800 1800 1800

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 60.2 55.7 64.7

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 17.4 14.4 20.4

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 5

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2100 2100 2100

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 17.4 14.4 20.4

Difference in delivery mm3/st. 4

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 385 385 385

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 8.9 6.9 10.9

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 385 385 385

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Average injection quantity mm3/st. 8.9 6.9 10.9

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

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. 60 60 100

Basic *

Oil temperature degC 48 46 50

Remarks
Full

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. 80 60 100

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 385 385 385

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

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 900 900 900

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Overflow quantity with S/T ON cm3/min 530 330 730

Overflow quantity with S/T OFF cm3/min 480 280 680

Oil temperature degC 50 48 52

Remarks
Without an O-ring

Stop lever angle

Pump speed r/min 1600 1600 1600

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Pressure with S/T OFF kPa 471 442 500

Pressure with S/T OFF kgf/cm2 4.8 4.5 5.1

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1600 1600 1600

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Pressure with S/T OFF kPa 471 442 500

Pressure with S/T OFF kgf/cm2 4.8 4.5 5.1

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1600 1600 1600

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T OFF mm 3.4 3.1 3.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T ON mm 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1440 1440 1440

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T OFF mm 0.5

Oil temperature degC 50 48 52

_04

Pump speed r/min 1600 1600 1600

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T OFF mm 3.4 3 3.8

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 1800 1800 1800

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T OFF mm 7.4 6.7 7.8

Oil temperature degC 50 48 52

_06

Pump speed r/min 1850 1850 1850

Boost pressure kPa -46.7 -48 -45.4

Boost pressure mmHg -350 -360 -340

Timer stroke with S/T OFF mm 7.4 7.1 7.8

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 3.1 3 3.2

KF dimension mm 5.5 5.4 5.6

MS dimension mm 0.4 0.3 0.5

Decrease stroke mm 2.2 2 2.4

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 31 26 36

Test data Ex:

0000001801 MICROSWITCH ADJUSTMENT

Microswitch adjustment (1)Insert a shim thickness t between the control lever and the full stopper screw and fix the control lever. (2)Move the microswitch adjusting plate in the direction of the arrow and fix the plate where the switch turns from ON to OFF. (3)After adjusting the microswitch, the distance between the plate and the roller at idle must not exceed L. (4)The plate must be adjusted to a position where the microswitch turns from ON to OFF. (5)Insert shim at FULL side. A:Idle position B:Plate
----------
t=1.3+-0.3mm L=2.5mm
----------
T=2.0~2.9N-m(0.2~0.3kgf-m) L=2.5--mm t=1.3+-0.3mm

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Adjust to obtain S. 2. Set at L when negative pressure P1 is applied to the actuator. To adjust the stroke adjust the actuator's stroke adjusting screw (C). (A) Control lever (B) Lock nut (Tightening torque T) (C) Stroke adjusting screw
----------
S=1+1mm L=1.6+-0.2mm P1=-53.3kPa(-400mmHg) T=1.2~1.5N-m(0.12~0.15kgf-m)
----------
S=1+1mm L=1.6+-0.2mm T=1.2~1.5N-m(0.12~0.15kgf-m)