104745-0170 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047450170

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Information injection-pump assembly

ZEXEL 104745-0170 1047450170

Cross reference number

ZEXEL 104745-0170 1047450170

Zexel num

Bosch num

Firm num

Name

104745-0170

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

(Solenoid timer adjustment condition)
With S/T O-ring; S/T ON. ON

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. 47.9 47.4 48.4

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 750 750 750

Boost pressure kPa 43.3 42 44.6

Boost pressure kgf/cm2 0.44 0.426 0.454

Boost pressure mmHg 325 315 335

Average injection quantity mm3/st. 64.1 63.6 64.6

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 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 69 68.5 69.5

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. 47.9 46.9 48.9

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 750 750 750

Boost pressure kPa 43.3 42 44.6

Boost pressure kgf/cm2 0.44 0.426 0.454

Boost pressure mmHg 325 315 335

Average injection quantity mm3/st. 64.1 63.1 65.1

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 69 68 70

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 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 63.1 59.6 66.6

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2450 2450 2450

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 23.5 19.5 23.5

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 6

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2450 2450 2450

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 23.5 13.5 33.5

Difference in delivery mm3/st. 7.5

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 370 370 370

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10.5 9.5 11.5

Difference in delivery mm3/st. 1.7

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 370 370 370

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10.5 9 12

Difference in delivery mm3/st. 2.2

Basic *

Oil temperature degC 48 46 50

Boost compensator 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. 17 15 19

Difference in delivery mm3/st. 3

Oil temperature degC 48 46 50

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. 70 55 90

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. 70 50 90

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 370 370 370

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 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Overflow quantity with S/T ON cm3/min 430 300 560

Overflow quantity with S/T OFF cm3/min 450 320 580

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure with S/T ON kPa 510 481 539

Pressure with S/T ON kgf/cm2 5.2 4.9 5.5

Pressure with S/T OFF kPa 422 383 461

Pressure with S/T OFF kgf/cm2 4.3 3.9 4.7

Basic *

Oil temperature degC 50 48 52

Remarks
ON

Stop lever angle_02

Pump speed r/min 500 500 500

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure with S/T ON kPa 353 304 402

Pressure with S/T ON kgf/cm2 3.6 3.1 4.1

Pressure with S/T OFF kPa 245 186 304

Pressure with S/T OFF kgf/cm2 2.5 1.9 3.1

Oil temperature degC 48 46 50

Stop lever angle_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure with S/T ON kPa 510 471 549

Pressure with S/T ON kgf/cm2 5.2 4.8 5.6

Pressure with S/T OFF kPa 422 373 471

Pressure with S/T OFF kgf/cm2 4.3 3.8 4.8

Basic *

Oil temperature degC 50 48 52

Remarks
ON

Stop lever angle_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure with S/T ON kPa 628 579 677

Pressure with S/T ON kgf/cm2 6.4 5.9 6.9

Pressure with S/T OFF kPa 549 490 608

Pressure with S/T OFF kgf/cm2 5.6 5 6.2

Oil temperature degC 50 48 52

Stop lever angle_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure with S/T ON kPa 736 687 785

Pressure with S/T ON kgf/cm2 7.5 7 8

Pressure with S/T OFF kPa 657 598 716

Pressure with S/T OFF kgf/cm2 6.7 6.1 7.3

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke with S/T ON mm 4.8 4.6 5

Timer stroke with S/T OFF mm 3.2 2.8 3.6

Basic *

Oil temperature degC 50 48 52

Remarks
ON

_02

Pump speed r/min 500 500 500

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke with S/T ON mm 2.2 1.4 3

Oil temperature degC 48 46 50

_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke with S/T ON mm 4.8 4.4 5.2

Timer stroke with S/T OFF mm 3.2 2.6 3.8

Basic *

Oil temperature degC 50 48 52

Remarks
ON

_04

Pump speed r/min 2000 2000 2000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke with S/T ON mm 9.4 8.6 10.2

Timer stroke with S/T OFF mm 7.8 6.8 8.8

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 3.3 3.2 3.4

KF dimension mm 6.01 5.91 6.11

MS dimension mm 0.9 0.8 1

BCS stroke mm 4.8 4.6 5

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:

0000001601 BOOST COMPENSATOR ADJUSTMENT

BCS adjustment procedure 1. At full boost pressure, set so that the full injection quantity is within the specifications (adjusting point). 2. Perform boost compensator intermediate operation point adjustment (pump speed N1, boost pressure P1). 3. When injection quantity at boost pressure P2 and pump speed N2 is not as specified, loosen nut (A) and adjust position of screw (B) so that injection quantity is as specified. The screw position should be within +-1 turn of initial position. 4. The nut tightening torque is T.
----------
N1=750r/min N2=750r/min P1=43.3kPa(325mmHg) P2=0kPa(0mmHg) T=6~9N-m(0.6~0.9kgf-m)
----------
SW=10mm T=6~9N-m(0.6~0.9kgf-m)

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

Adjustment of the potentiometer Dummy bolt method 1. Hold the dummy bolt against the control lever at position N = N1 and Q = Q1 and fix using the lock nut. 2. At potentiometer adjustment, with the control lever contacting the dummy bolt, adjust the potentiometer so that the output voltage is V1. 3. After adjustment, remove the dummy bolt and confirm that the potentiometer output voltage at the control lever's idling and full speed positions is as specified above. N:Pump speed P:Boost pressure Q:Injection quantity V:Output voltage A:Adjusting point B:Checking point C/L: control lever position I:Idling F:Full speed Vi:Applied voltage
----------
N1=1000r/min Q1=24.6+1.5+0.1mm3/st V1=4.81+0.01-0.05V
----------
N1=1000r/min P1=80.0kPa(600mmHg) Q1=24.6+1.5+0.1mm3/st V1=4.81+0.01-0.05V V2=2.0+-0.43V V3=8.5+-0.48V Vi=10V

0000002001 WIRE

1. Wire length confirmation Accelerator wire: Idle-full stroke: L1 2. Idle switch confirmation Confirm that the switch is ON in the control lever's idle position. 3. Adjustment of the 2-stage actuator: (1)Apply negative pressure P1 to the actuator through the negative pressure inlet port (A). (2)Confirm that the potentiometer output voltage is within the specifications with the control lever in the idle position. (3)Lock nut (E) tightening torque T2.
----------
L1=34.1+3.5-5.5mm L2=3.8+-0.5mm P1=-66.6kPa(-500mmHg) a=6.6deg T1=6~9N-m(0.6~0.9kgf-m) T2=12~15N-m(1.2~1.5kgf-m)
----------
a=6.6deg b=12.5+-4deg L2=3.8+-0.5mm

0000002101 DASHPOT ADJUSTMENT

Adjustment of the dash pot 1. Hold the control lever (A) at position a (clearance L). 2. In the above condition, adjust the position of the dash pot so that the end of the dash pot (B) contacts the control lever (A) and fix using the nut (C). (Tightening torque T) D:Dash pot contact position b:Angle alpha
----------
a=14.1deg L=8.1+-0.05mm T=6~9N-m(0.6~0.9kgf-m)
----------
D=14.1deg L=8.1+-0.05mm b=12.5+-4deg