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Information injection-pump assembly
ZEXEL
104745-0040
1047450040
Cross reference number
ZEXEL
104745-0040
1047450040
Zexel num
Bosch num
Firm num
Name
104745-0040
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
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
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)
Left L
Left L
Injection timing adjustment
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
48.7
48.2
49.2
Difference in delivery
mm3/st.
4
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
44.8
41.8
47.8
Oil temperature
degC
48
46
50
Injection timing adjustment_03
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
48.7
47.7
49.7
Difference in delivery
mm3/st.
4.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
2100
2100
2100
Average injection quantity
mm3/st.
44.3
40.8
47.8
Oil temperature
degC
52
50
54
Injection quantity adjustment
Pump speed
r/min
2450
2450
2450
Average injection quantity
mm3/st.
15.7
12.7
18.7
Difference in delivery
mm3/st.
5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_02
Pump speed
r/min
2700
2700
2700
Average injection quantity
mm3/st.
8
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2450
2450
2450
Average injection quantity
mm3/st.
15.7
5.7
25.7
Difference in delivery
mm3/st.
5.5
Basic
*
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
9
8
10
Difference in delivery
mm3/st.
1.7
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
9
7.5
10.5
Difference in delivery
mm3/st.
2.2
Basic
*
Oil temperature
degC
48
46
50
Boost compensator adjustment
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
17
15
19
Difference in delivery
mm3/st.
3
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
70
55
90
Basic
*
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
70
50
90
Oil temperature
degC
48
46
50
Remarks
Full
Full
Speed control lever angle
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
0000000901
Pump speed
r/min
1250
1250
1250
Overflow quantity with S/T ON
cm3/min
420
290
550
Overflow quantity with S/T OFF
cm3/min
460
330
590
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
1250
1250
1250
Pressure with S/T ON
kPa
569
530
608
Pressure with S/T ON
kgf/cm2
5.8
5.4
6.2
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
Remarks
OFF
OFF
Stop lever angle_02
Pump speed
r/min
1250
1250
1250
Pressure with S/T OFF
kPa
471
432
510
Pressure with S/T OFF
kgf/cm2
4.8
4.4
5.2
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
0000001101
Pump speed
r/min
1250
1250
1250
Timer stroke with S/T ON
mm
5.7
5.3
6.1
Timer stroke with S/T OFF
mm
4.1
3.9
4.3
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_02
Pump speed
r/min
500
500
500
Timer stroke with S/T ON
mm
1.8
0.8
2.8
Oil temperature
degC
48
46
50
_03
Pump speed
r/min
1250
1250
1250
Timer stroke with S/T ON
mm
5.7
5.1
6.3
Timer stroke with S/T OFF
mm
4.1
3.7
4.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_04
Pump speed
r/min
2000
2000
2000
Timer stroke with S/T ON
mm
9.2
8.2
10
Timer stroke with S/T OFF
mm
7.6
7
8.2
Oil temperature
degC
50
48
52
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001401
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
35.6
35.1
36.1
Timer stroke TA
mm
3.8
3.8
3.8
Timer stroke variation dT
mm
0.3
0.1
0.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_02
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
35.6
34.6
36.6
Timer stroke variation dT
mm
0.3
-0.1
0.7
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_03
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
22.1
20.6
23.6
Timer stroke variation dT
mm
1
0.5
1.5
Oil temperature
degC
50
48
52
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
6.01
5.91
6.11
MS dimension
mm
0.9
0.8
1
Pre-stroke
mm
0.03
0.01
0.05
Control lever angle alpha
deg.
12.5
8.5
16.5
Control lever angle beta
deg.
40
37
43
Test data Ex:
0000001801 CONTROL STANDARD AT IDLING
Standards for idle difference in delivery control
After idle adjustment, measure the idle injection quantities of (A) to (D).
Install the colored rings to the delivery valve holders (A) to (D) in accordance with the table.
(A): A cylinder (B) :B cylinder (C) : C cylinder (D): D cylinder
(E): Collar ring
(F): (A) >= (C)
(G): (C) > (A)
(H): (A) - (C) or (C) - (A)
(I): 0.2, 0.1(mm3/st)
(J): (B) - (D) or (D) - (B)
(K): Ring color
(L): At least 0.6 mm3/st
(M): 0.3, 0.4, 0.5 (mm3/st)
(N): 0.2, 0.1, 0.0 (mm3/st)
(O): (B) >= (D)
(P): (D) > (B)
(T): Yellow
(U): White
(V): Red
----------
----------
----------
----------
0000001901 POTENTIOMETER ADJUSTMENT
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 to contact the dummy bolt. Adjust the potentiometer so that the output voltage is V1.
3. Remove the dummy bolt after the completion of adjustment.
Move the control lever and confirm that the potentiometer output voltage is within the above-mentioned standards.
N:Pump speed
Q:Injection quantity
V:Output voltage
C:Position of the control lever
C1:Idle
C2:Full
A:Adjusting point
B:Checking point
P:Boost pressure
Vi:Applied voltage
----------
N1=1500(r/min) Vi=10(V) Q1=15.2+-1.0(cm3/1,000st) V1=4.97+-0.03(V)
----------
N1=1500r/min Vi=10V Q1=15.2+-1.0cm3/1,000st V1=4.97+-0.03V V2=1.73+-0.70V V3=8.40+-0.53V a=18.0deg b=0deg c=40.0+-3.0deg P1=0kPa P2=0mmHg
----------
N1=1500(r/min) Vi=10(V) Q1=15.2+-1.0(cm3/1,000st) V1=4.97+-0.03(V)
----------
N1=1500r/min Vi=10V Q1=15.2+-1.0cm3/1,000st V1=4.97+-0.03V V2=1.73+-0.70V V3=8.40+-0.53V a=18.0deg b=0deg c=40.0+-3.0deg P1=0kPa P2=0mmHg
0000002001 WIRE
(1)Wire length confirmation
Accelerator wire: Idle-full stroke: L1 mm
(2)Idle switch confirmation
Confirm that the switch is ON in the idle lever position.
(3)2 stage lever adjustment
1. Apply negative pressure P1 kPa {P2 mmHg} to the negative pressure suction inlet.
2. Under the conditions in 1, adjust with the screw (C) so that the position of the control lever (B) becomes angle a [gap L2 from the idle screw (E)] and fix the nut (D).
T:Tightening torque
----------
L1=34.1+-3.5mm L2=4.6+-0.5mm P1=-66.0kPa P2=-500mmHg a=7.6deg T=6~9N-m(0.6~0.9Kgf-m)
----------
a=7.6deg b=12.5+-4deg L2=4.6mm
----------
L1=34.1+-3.5mm L2=4.6+-0.5mm P1=-66.0kPa P2=-500mmHg a=7.6deg T=6~9N-m(0.6~0.9Kgf-m)
----------
a=7.6deg b=12.5+-4deg L2=4.6mm
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104745-0040
INJECTION-PUMP ASSEMBLY