104748-2490 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047482490

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104748-2490 1047482490

Cross reference number

ZEXEL 104748-2490 1047482490

Zexel num

Bosch num

Firm num

Name

104748-2490

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 1000 1000 1000

Average injection quantity mm3/st. 27 26.6 27.4

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 26.6 24.6 28.6

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 28 27 29

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 29 27 31

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 28.3 26.3 30.3

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 14.8 12.8 16.8

Difference in delivery mm3/st. 4.5

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

Injection quantity adjustment_03

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 27.4 25.4 29.4

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 5.1 4.1 6.1

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 5.1 3.1 7.1

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Boost compensator adjustment

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 15.2 10.7 19.7

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 8.9 8.9 8.9

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 12.4 7.4 17.4

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 8.9 8.9 8.9

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 52.5 47.5 57.5

Basic *

Oil temperature degC 48 46 50

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 47.5 42.5 52.5

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 360 360 360

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 1200 1200 1200

Overflow quantity cm3/min 350 220 480

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1200 1200 1200

Pressure kPa 373 344 402

Pressure kgf/cm2 3.8 3.5 4.1

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1200 1200 1200

Pressure kPa 372.5 333 412

Pressure kgf/cm2 3.8 3.4 4.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Pressure kPa 510 471 549

Pressure kgf/cm2 5.2 4.8 5.6

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2500 2500 2500

Pressure kPa 667 628 706

Pressure kgf/cm2 6.8 6.4 7.2

Oil temperature degC 55 52 58

0000001101

Pump speed r/min 1200 1200 1200

Timer stroke mm 2.9 2.7 3.1

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Timer stroke mm 1.6 1.2 2

Oil temperature degC 50 48 52

_03

Pump speed r/min 1200 1200 1200

Timer stroke mm 2.9 2.6 3.2

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 2500 2500 2500

Timer stroke mm 8.15 7.7 8.6

Oil temperature degC 55 52 58

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 16.5 15.5 17.5

Timer stroke TA mm 2.3 2.1 2.5

Timer stroke variation dT mm 0.6 0.6 0.6

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 14 12 16

Timer stroke TA mm 1.7 1.3 2.1

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. 25 23 27

Control lever angle beta deg. 44 39 49

Test data Ex:

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
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L=5.9~8.2mm

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 (J) and position it perpendicularly. 3. W-CSD lever adjustment [refer to fig 1 (O) and fig 2 (P)] (1)After completing (2) above, remove the block gauge L2. (2)Insert a block gauge (I) L3 determined from the graph (L-theta) in figure 3 (Q) between the idling set screw (G) and the control lever (F). (3)Fix screw (B) so that the W-CSD lever (C)'s roller contacts the intermediate lever (D). Fix using the nut. Note: The temperature of the wax at adjustment must not exceed a. X:Temperature theta (deg C) Y1:Timer stroke TA (mm) Y2:Control lever L dimension (mm; control lever position) K:Vertical position M:TA-theta line 10 <= theta (deg C) <= 20: TA = -0.0355 theta + 1.995 20 <= theta (deg C) <= 57: TA = -0.03515 theta + 1.988 N:L-theta graph theta (deg C) <= 10: L = 4.6 10 < theta (deg C) <= 20: L = -0.17theta + 6.3 20 < theta (deg C) <= 28.5: L = -0.235 theta + 7.6 28.5 < theta (deg C) <= 36: L = -0.012 theta + 4.32
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L1=L=2.9+-0.05mm L2=2.9mm L3=L+-0.05mm a=30degC
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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
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N1=700r/min a=14deg L=8.9mm
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J:V+-0.05=0.1333Q+2.69 (V)