104745-3750 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047453750

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104745-3750 1047453750

Cross reference number

ZEXEL 104745-3750 1047453750

Zexel num

Bosch num

Firm num

Name

104745-3750

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 44 42.7 45.3

Boost pressure mmHg 330 320 340

Average injection quantity mm3/st. 59.9 59.4 60.4

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 62.2 61.7 62.7

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 48.9 46.4 51.4

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 44 42.7 45.3

Boost pressure mmHg 330 320 340

Average injection quantity mm3/st. 59.9 58.9 60.9

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_05

Pump speed r/min 1000 1000 1000

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 63.3 63.3 63.3

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 62.2 61.2 63.2

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 1750 1750 1750

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 59 59 59

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 2100 2100 2100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 55.3 52.8 57.8

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2650 2650 2650

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 27.1 24.1 30.1

Difference in delivery mm3/st. 8.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 3050 3050 3050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2650 2650 2650

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 27.1 22.1 32.1

Difference in delivery mm3/st. 9

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 14.5 13 16

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 14.5 12.5 16.5

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 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 mmHg 0 0 0

Average injection quantity mm3/st. 80 70 90

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 mmHg 0 0 0

Average injection quantity mm3/st. 80 70 90

Oil temperature degC 48 46 50

Remarks
IDLE

Speed control lever angle

Pump speed r/min 375 375 375

Boost pressure kPa 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 73.3 72 74.6

Boost pressure mmHg 550 540 560

Overflow quantity cm3/min 420 290 550

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 471 442 500

Pressure kgf/cm2 4.8 4.5 5.1

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 3.7 3.5 3.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 500 500 500

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 1.2 0.6 1.8

Oil temperature degC 48 46 50

_03

Pump speed r/min 750 750 750

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 2 1.4 2.6

Oil temperature degC 50 48 52

_04

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 3.7 3.3 4.1

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 1750 1750 1750

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 5.8 5.2 6.4

Oil temperature degC 50 48 52

_06

Pump speed r/min 2100 2100 2100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 7.2 6.6 7.8

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 49 48.5 49.5

Timer stroke TA mm 3.1 3.1 3.1

Timer stroke variation dT mm 0.6 0.4 0.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 49 48 50

Timer stroke variation dT mm 0.6 0.2 1

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 36 35 37

Timer stroke variation dT mm 1.4 0.8 2

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 1 0.9 1.1

Control lever angle alpha deg. 57 53 61

Control lever angle beta deg. 43 38 48

Test data Ex:

0000001801 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):
----------

----------
(C)=TA=-0.0376t+1.38(-20<=t)

0000001901 W-FICD LEVER ADJUSTMENT

2. Adjustment of the W-FICD (1)Insert a block gauge L1 determined from the graph between the control lever (D) and the idling stopper bolt (C). (2)Insert a shim t between the W-CSD lever (E) and the control lever(F). Adjust the W-CSD lever (E) so that it contacts the control lever (F), then fix using the bolt (B). (Tightening torque T). After completing adjustment, screw (G)'s margin must be at least S. Also, remove the block gauge and shims. Note: The temperature of the wax at adjustment must not exceed a. Y:Control lever L (mm) X:Temperature (deg C) H:Block gauge thickness L diagram I
----------
L1=L+-0.05mm t=3+-0.05mm T=3.4~4.9N-m(0.35~0.5kgf-m) a=30degC S=3mm
----------
t=3mm S=Above3mm I=L=-0.201X+8.65(-20<=X) (t=3+-0.05)

0000002001 ACCELERATOR LINK STROKE

A/T plate adjustment Rotate the control lever from the idle position (B) to the full-speed position (C). Adjust the accelerator link stroke so that (A) (C) - (A) (B) = L3, and fix. (B): B idle position (C): B' full
----------
L3=32.9+-1mm
----------
L1=20.9mm L2=223mm