104749-2422 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047492422

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104749-2422 1047492422

Cross reference number

ZEXEL 104749-2422 1047492422

Zexel num

Bosch num

Firm num

Name

104749-2422

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)
Right R

Injection timing adjustment

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 30.4 30 30.8

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. 30.6 28.6 32.6

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 30.4 29.4 31.4

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 31.8 29.8 33.8

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 30.8 28.8 32.8

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 30.5 28.5 32.5

Oil temperature degC 52 50 54

Injection timing adjustment_07

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 30.2 28.2 32.2

Oil temperature degC 55 52 58

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 14.5 12.5 16.5

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 14.5 11 18

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 6

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 5.2 4.2 6.2

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 5.2 3.2 7.2

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 3

Oil temperature degC 48 46 50

Boost compensator adjustment

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 12.1 7.6 16.6

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 7.2 7.15 7.25

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 7 2 12

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 7.2 7.15 7.25

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 40 40 60

Basic *

Oil temperature degC 48 46 50

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50 40 60

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

Speed control lever angle_02

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 50 48 52

Remarks
Magnet OFF at full-load position

0000000901

Pump speed r/min 900 900 900

Overflow quantity cm3/min 330 200 460

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 900 900 900

Pressure kPa 343 314 372

Pressure kgf/cm2 3.5 3.2 3.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 900 900 900

Pressure kPa 343 304 382

Pressure kgf/cm2 3.5 3.1 3.9

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Pressure kPa 539.5 500 579

Pressure kgf/cm2 5.5 5.1 5.9

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2300 2300 2300

Pressure kPa 706 667 745

Pressure kgf/cm2 7.2 6.8 7.6

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 900 900 900

Timer stroke mm 1.5 1.3 1.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Timer stroke mm 1.5 1.2 1.8

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1200 1200 1200

Timer stroke mm 3 2.7 3.3

Oil temperature degC 50 48 52

_04

Pump speed r/min 2300 2300 2300

Timer stroke mm 8.4 7.8 9

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 1.2 1.1 1.3

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 41 36 46

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer (1)At pump speed N1 and oil temperature t, and at lever angle a from the idle position (shim thickness L), determine the voltage value from the graph using the injection quantity obtained. Then adjust the potentiometer. V+-0.05 = 0.155323Q + 2.43145 (applied voltage Vi) (2)With the control lever turned to the full speed side, confirm that voltage increases. (3)Confirm V1 or less at idling. Q:Injection quantity
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N1=600(r/min) t=48~52(deg) a=11(deg) L=7.2+-0.05(mm) Vi=10(V) V1=1.6(V)
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0000001901 M-CSD ADJUSTMENT

M-CSD adjustment 1. Fixing intermediate lever screw (A) [roller (E) must not contact intermediate lever (D)] (1)Hold the control lever (C) in the idling position. (2)At this time, adjust screw (A) so that it is horizontal and the clearance between screw (A) and the control lever (C) is L1. Then, fix using nut (B). 2. Fixing the M-CSD stopper (I) Pull the CSD lever (F) in the direction X until it contacts the stopper (I) and tighten the socket head bolt (J) when the timer advance angle is L2. 3. Screw (G) adjustment Pull the CSD lever (F) in the direction X until it contacts the stopper (I) and adjust the screw (G) so that the control lever shim thickness is L3. Then, tighten nut (H).
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L1=1~2(mm) L2=1.23+-0.2(mm) L3=7.2+-0.5(mm)
----------
T1=6~9(N-m)(0.6~0.9(kgf-m)) T2=5~7(N-m)(0.5~0.7(kgf-m)) T3=2~3(N-m)(0.2~0.3(kgf-m)) L1=1~2(mm) L3=7.2+-0.5(mm)