104745-0041 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047450041

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104745-0041 1047450041

Cross reference number

ZEXEL 104745-0041 1047450041

Zexel num

Bosch num

Firm num

Name

104745-0041

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)
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

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

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

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

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

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

_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

_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

_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

_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
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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
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N1=1500r/min Q1=15.2+-1.0cm3/1,000st V1=4.97+-0.03V
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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

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
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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)
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a=7.6deg b=12.5+-4deg L2=4.6mm