104748-2222 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047482222

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104748-2222 1047482222

Cross reference number

ZEXEL 104748-2222 1047482222

Zexel num

Bosch num

Firm num

Name

104748-2222

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
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

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 1200 1200 1200

Average injection quantity mm3/st. 29.1 28.6 29.6

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 14.9 11.4 18.4

Oil temperature degC 55 52 58

Injection timing adjustment_03

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 27.7 25.7 29.7

Oil temperature degC 55 52 58

Injection timing adjustment_04

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 29.1 28.1 30.1

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 26.3 24.3 28.3

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 14.9 11.9 17.9

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2900 2900 2900

Average injection quantity mm3/st. 6

Oil temperature degC 55 52 58

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 *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 6.8 4.8 8.8

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 3

Oil temperature degC 50 48 52

Boost compensator adjustment

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 15 10 20

Oil temperature degC 50 48 52

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50.3 45.3 55.3

Basic *

Oil temperature degC 48 46 50

Remarks
Refer to additional devices.

Speed control lever angle

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF

0000000901

Pump speed r/min 1200 1200 1200

Overflow quantity cm3/min 348 216 480

Oil temperature degC 50 48 52

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 *

Oil temperature degC 50 48 52

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

Oil temperature degC 50 48 52

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

Oil temperature degC 50 48 52

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

Oil temperature degC 55 52 58

0000001101

Pump speed r/min 1200 1200 1200

Timer stroke mm 2.6 2.3 2.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 800 800 800

Timer stroke mm 1.1 0.5 1.7

Oil temperature degC 50 48 52

_03

Pump speed r/min 1200 1200 1200

Timer stroke mm 2.6 2.2 3

Oil temperature degC 50 48 52

_04

Pump speed r/min 2500 2500 2500

Timer stroke mm 7.95 7.4 8.5

Oil temperature degC 55 52 58

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

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 1.8 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 Adjust the ACS so that the reduction amount corresponds to the altitude in the table. X1 = atmospheric pressure X2 = altitude Y = decrease quantity (A) = adjustment value (B) = test value
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N1=1200r/min
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0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer At pump speed N = N1 r/min and with the control lever angle at a from the idle position (corresponding to a shim thickness of L mm), convert the injection quantity obtained to a voltage value using the graph and adjust the potentiometer. Vi:Applied voltage E = conversion expression Vo = output voltage Q = injection quantity
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N1=700r/min a=14deg L=8.9mm
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J=V+-0.05=0.187Q+1.593 V Vi=-V

0000001901 STARTING I/Q ADJUSTMENT

Starting injection quantity adjustment Adjust the adjusting bolt (A) so that the starting injection quantity is within the standard and fix using the locknut (B). (C) Stop lever
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0000002001 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) and then tighten the nut. 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). 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 = -0.0367t + 1.284 20 <= t (deg C) <= 40: TA = -0.0275t + 1.1 K:Graph L-X: -10<= t (deg C) <= 20: L = -0.0867t + 3.63 20 <= t (deg C) <= 40: L = -0.075 t + 3.4
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L1=1.9+-0.05mm L2=L+-0.05mm a=30degC
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