104746-6601 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047466601


104746-6601 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 104746-6601 1047466601

Cross reference number

ZEXEL 104746-6601 1047466601


Zexel num
Bosch num
Firm num
Name
104746-6601 
 
   
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
Timer measuring device installation position
Low pressure side
  LOW PRESSURE SIDE
Injection timing adjustment
Pump speed r/min   500 500 500
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   60.5 60 61
Difference in delivery mm3/st.   5
Basic   *
Oil temperature degC   48 46 50
Remarks
NA
 
Injection timing adjustment_02
Pump speed r/min   800 800 800
Boost pressure kPa   52 50.7 53.3
Boost pressure mmHg   390 380 400
Average injection quantity mm3/st.   67.4 66.9 67.9
Difference in delivery mm3/st.   5.5
Basic   *
Oil temperature degC   50 48 52
Remarks
CBS
 
Injection timing adjustment_03
Pump speed r/min   800 800 800
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   76.8 76.3 77.3
Difference in delivery mm3/st.   6
Basic   *
Oil temperature degC   50 48 52
Remarks
Full
 
Injection timing adjustment_04
Pump speed r/min   500 500 500
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   60.5 59.5 61.5
Difference in delivery mm3/st.   5
Basic   *
Oil temperature degC   48 46 50
Remarks
NA
 
Injection timing adjustment_05
Pump speed r/min   800 800 800
Boost pressure kPa   52 50.7 53.3
Boost pressure mmHg   390 380 400
Average injection quantity mm3/st.   67.4 66.4 68.4
Difference in delivery mm3/st.   5.5
Basic   *
Oil temperature degC   50 48 52
Remarks
CBS
 
Injection timing adjustment_06
Pump speed r/min   800 800 800
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   76.8 75.8 77.8
Difference in delivery mm3/st.   6
Basic   *
Oil temperature degC   50 48 52
Remarks
Full
 
Injection timing adjustment_07
Pump speed r/min   1000 1000 1000
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   83.8 77.3 90.3
Oil temperature degC   50 48 52
Injection timing adjustment_08
Pump speed r/min   1250 1250 1250
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   91.5 85 98
Oil temperature degC   50 48 52
Injection timing adjustment_09
Pump speed r/min   1700 1700 1700
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   105.7 99.2 112.2
Oil temperature degC   50 48 52
Injection quantity adjustment
Pump speed r/min   2075 2075 2075
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   34 31 37
Difference in delivery mm3/st.   7
Basic   *
Oil temperature degC   52 50 54
Injection quantity adjustment_02
Pump speed r/min   2300 2300 2300
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   3
Oil temperature degC   52 50 54
Injection quantity adjustment_03
Pump speed r/min   2075 2075 2075
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Average injection quantity mm3/st.   34 31 37
Difference in delivery mm3/st.   7
Basic   *
Oil temperature degC   52 50 54
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.   13.9 11.9 15.9
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.   13.9 11.9 15.9
Difference in delivery mm3/st.   2
Basic   *
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.   60 60 100
Oil temperature degC   48 46 50
Remarks
Full
 
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   1350 1350 1350
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Overflow quantity cm3/min   1080 850 1310
Oil temperature degC   50 48 52
Stop lever angle
Pump speed r/min   1350 1350 1350
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Pressure kPa   471 442 500
Pressure kgf/cm2   4.8 4.5 5.1
Basic   *
Oil temperature degC   50 48 52
Stop lever angle_02
Pump speed r/min   1020 1020 1020
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Pressure kPa   353 314 392
Pressure kgf/cm2   3.6 3.2 4
Oil temperature degC   50 48 52
Stop lever angle_03
Pump speed r/min   1250 1250 1250
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Pressure kPa   432 393 471
Pressure kgf/cm2   4.4 4 4.8
Oil temperature degC   50 48 52
Stop lever angle_04
Pump speed r/min   1350 1350 1350
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Pressure kPa   471 442 500
Pressure kgf/cm2   4.8 4.5 5.1
Basic   *
Oil temperature degC   50 48 52
Stop lever angle_05
Pump speed r/min   1500 1500 1500
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Pressure kPa   510 471 549
Pressure kgf/cm2   5.2 4.8 5.6
Oil temperature degC   50 48 52
Stop lever angle_06
Pump speed r/min   1800 1800 1800
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Pressure kPa   628 589 667
Pressure kgf/cm2   6.4 6 6.8
Oil temperature degC   50 48 52
0000001101
Pump speed r/min   1350 1350 1350
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Timer stroke mm   1.8 1.6 2
Basic   *
Oil temperature degC   50 48 52
_02
Pump speed r/min   1020 1020 1020
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Timer stroke mm   0.5
Oil temperature degC   50 48 52
_03
Pump speed r/min   1350 1350 1350
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Timer stroke mm   1.8 1.6 2
Basic   *
Oil temperature degC   50 48 52
_04
Pump speed r/min   1500 1500 1500
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Timer stroke mm   3 2.6 3.4
Oil temperature degC   50 48 52
_05
Pump speed r/min   1800 1800 1800
Boost pressure kPa   80 78.7 81.3
Boost pressure mmHg   600 590 610
Timer stroke mm   4.5 4.2 4.9
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   3.6 3.5 3.7
KF dimension mm   7.76 7.66 7.86
MS dimension mm   0.8 0.7 0.9
BCS stroke mm   2.6 2.4 2.8
Pre-stroke mm   0.2 0.18 0.22
Control lever angle alpha deg.   18 14 22
Control lever angle beta deg.   37 32 42

Test data Ex:

0000001601 BOOST COMPENSATOR ADJUSTMENT

Test data 104746-6601
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=800r/min N2=500r/min P1=52.0kPa(390mmHg) P2=0kPa(0mmHg) T=6~9N-m(0.6~0.9kgf-m)
----------
SW=10mm T=6~9N-m(0.6~0.9kgf-m)

0000001801 POTENTIOMETER ADJUSTMENT

Test data 104746-6601
Potentiometer adjusting specifications (oval) N:Pump speed Q:Injection quantity P:Boost pressure V:Output voltage C/L: control lever position I:Idle F:Full lever position B:Adjusting point C:Checking point D:Bracket (shape may differ) Adjusting method (applied voltage Vi, dummy bolt method) 1. Hold the dummy bolt (A) 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 completing adjustment, remove the dummy bolt (A) and confirm that the potentiometer output voltage is within the adjustment specifications when the control lever is in the idle position. (A): Dummy bolt and nut part number 146526-3300 (bolt) corresponding to 42 (mm). Corresponding to 013020-6040 (nut)
----------
N1=1080r/min Q1=27.5+-1.0mm3/st V1=3.56+-0.03V Vi=10V
----------
N1=1080r/min N2=375r/min P1=0kPa(0mmHg) Q1=27.5+-1.0mm3/st Q2=13.9+-2.0mm3/st V1=3.56+-0.03V V2=(0.93+-0.45V) V3=(7.10+-0.83V) Vi=10V




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