Rating:
Information injection-pump assembly
ZEXEL
104748-2020
1047482020
Cross reference number
ZEXEL
104748-2020
1047482020
Zexel num
Bosch num
Firm num
Name
104748-2020
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
105000-2010
Bosch type code
NP-DN12SD12TT
Nozzle holder
105780-2080
Opening pressure
MPa
14.7
14.7
15.19
Opening pressure
kgf/cm2
150
150
155
Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840
Inside diameter - outside diameter - length (mm) mm 2-6-840
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
1200
1200
1200
Average injection quantity
mm3/st.
29.1
28.6
29.6
Difference in delivery
mm3/st.
2.5
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2700
2700
2700
Average injection quantity
mm3/st.
14.9
11.4
18.4
Injection timing adjustment_03
Pump speed
r/min
2500
2500
2500
Average injection quantity
mm3/st.
27.7
25.7
29.7
Injection timing adjustment_04
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
29.1
28.1
30.1
Injection timing adjustment_05
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
26.3
24.3
28.3
Injection quantity adjustment
Pump speed
r/min
2700
2700
2700
Average injection quantity
mm3/st.
14.9
11.9
17.9
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
2900
2900
2900
Average injection quantity
mm3/st.
6
Governor adjustment
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
6.8
5.3
8.3
Difference in delivery
mm3/st.
3
Basic
*
Governor adjustment_02
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
6.8
4.8
8.8
Governor adjustment_03
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
3
Boost compensator adjustment
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
15
10
20
Remarks
From idle
From idle
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
50.3
45.3
55.3
Basic
*
Speed control lever angle
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF
Magnet OFF
0000000901
Pump speed
r/min
1200
1200
1200
Overflow quantity
cm3/min
348
216
480
Stop lever angle
Pump speed
r/min
1200
1200
1200
Pressure
kPa
333.5
304
363
Pressure
kgf/cm2
3.4
3.1
3.7
Basic
*
Stop lever angle_02
Pump speed
r/min
1200
1200
1200
Pressure
kPa
333.5
294
373
Pressure
kgf/cm2
3.4
3
3.8
Stop lever angle_03
Pump speed
r/min
1800
1800
1800
Pressure
kPa
470.5
431
510
Pressure
kgf/cm2
4.8
4.4
5.2
Stop lever angle_04
Pump speed
r/min
2500
2500
2500
Pressure
kPa
637.5
598
677
Pressure
kgf/cm2
6.5
6.1
6.9
0000001101
Pump speed
r/min
1200
1200
1200
Timer stroke
mm
2.6
2.3
2.9
Basic
*
_02
Pump speed
r/min
1200
1200
1200
Timer stroke
mm
2.6
2.2
3
_03
Pump speed
r/min
1800
1800
1800
Timer stroke
mm
4.9
4.3
5.5
_04
Pump speed
r/min
2500
2500
2500
Timer stroke
mm
8
7.4
8.6
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001501
Pump speed
r/min
1200
1200
1200
Atmospheric pressure difference
kPa
-18.7
-19.4
-18
Atmospheric pressure difference
mmHg
-140
-145
-135
Decrease qty
mm3/st.
2.6
1.1
4.1
Remarks
MEASURE
MEASURE
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.8
5.7
5.9
MS dimension
mm
1.8
1.7
1.9
Control lever angle alpha
deg.
24
20
28
Control lever angle beta
deg.
44
39
49
Control lever angle gamma
deg.
14
13.5
14.5
Test data Ex:
0000001501 ANEROID COMPENSATOR
ACS adjustment
Full load injection quantity at high altitudes and ACS adjusting method
1. Full load injection quantity adjustment
(1)Remove the ACS cover and remove the bellows and adjusting shim.
(2)Perform all adjustments as per the adjustment standard except for ACS adjustment.
2. ACS adjustment
(1)Assemble the ACS cover, bellows and adjusting shim.
(2)At pump speed N1, adjust using a shim to obtain the decrease for the altitude shown in the table.
X1 = atmospheric pressure
X2 = altitude
Y = decrease quantity
(A) = adjustment value
(B) = test value
----------
N1=1200r/min
----------
----------
N1=1200r/min
----------
0000001801 STARTING I/Q ADJUSTMENT
Starting injection quantity adjustment
Adjust adjusting bolt so that the starting injection quantity is within the standard.
Fix using nut.
(A): Lock nut.
(B): Stopping lever
(C): Adjustment bolt
----------
----------
----------
----------
0000001901 W-CSD ADJUSTMENT
Adjustment of the W-CSD
1. Timer advance adjustment (refer to Fig 1 [O], 3 [Q]).
(1)Determine the timer advance angle from the graph in Fig. 3 (Q).
(2)(1) Adjust with the screw (A) so that the timer advance angle determined in the item (1) is obtained.
2. Setting the intermediate lever position (refer to fig 1 and fig 2)
(1)Insert a block gauge L1 between the idling set screw (G) and the control lever (F).
(2)Align the intermediate lever (D) with the aligning line and position it perpendicularly. Adjust the screw (E) so that it contacts the control lever (F), then turn the screw 0.5 ~ 1 turns counterclockwise and fix.
[At this time, tilt the intermediate lever clockwise b from a perpendicular position to obtain L3 shown in Figure 1 (O).]
3. W-CSD lever adjustment [refer to fig 1 (O) and fig 2 (P)]
(1)Insert a block gauge L2 determined from the graph (L-t) in figure 3 (Q) between the idling set screw (G) and the control lever (F).
(2)Fix screw (B) so that the W-CSD lever (C)'s roller contacts the intermediate lever (D).
Adjust the screw (B) until the screw (F) contacts the control lever (G). Then fix locknut (A).
Note:
Apply red paint after adjustment.
When inserting the block gauge, separate lever (C) and (D) using screw (B) to prevent excessive force on the lever.
X = temperature t (V)
Y1 = timer lift TA (mm)
Y2 = control lever dimension L mm (control lever position
J = graph TA - t
-10 <= t (deg C) <= 20: TA = -0.028t + 1.367
20 <= t (deg C) <= 60: TA = -0.02 t + 1.2
K:Graph L-t
-10 <= t (deg C) <= 20: L = -0.0667t + 3.23
20 <= t (deg C) <= 60: L = -0.05 t + 2.9
----------
L1=10+-0.05mm L2=L+-0.05mm L3=(44)mm a=30degC b=1~3degC
----------
L3=(44)mm
----------
L1=10+-0.05mm L2=L+-0.05mm L3=(44)mm a=30degC b=1~3degC
----------
L3=(44)mm
0000002001 POTENTIOMETER ADJUSTMENT
Adjustment of the potentiometer
At pump speed N = N1 and with the control lever angle at a from the idle position (corresponding to a shim thickness of L), convert the injection quantity obtained to a voltage value using the graph and adjust the potentiometer.
Caution: Confirm that the voltage increases when the control lever is turned to the full speed side.
E:J = formula
Vi:Applied voltage
Vo = output voltage
Q = injection quantity
----------
N1=700r/min a=14deg L=8.9mm
----------
J=V+-0.05=0.187Q+1.593 V Vi=-V
----------
N1=700r/min a=14deg L=8.9mm
----------
J=V+-0.05=0.187Q+1.593 V Vi=-V
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104748-2020
INJECTION-PUMP ASSEMBLY