104749-5290 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047495290

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Information injection-pump assembly

ZEXEL 104749-5290 1047495290

Cross reference number

ZEXEL 104749-5290 1047495290

Zexel num

Bosch num

Firm num

Name

104749-5290

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)
Right R

Injection timing adjustment

Pump speed r/min 900 900 900

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 47.4 46.9 47.9

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 52.3 51.8 52.8

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 39.6 36.6 42.6

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 31.3 30 32.6

Boost pressure mmHg 235 225 245

Average injection quantity mm3/st. 46.9 46.9 46.9

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 900 900 900

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 47.4 46.4 48.4

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1500 1500 1500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 37.4 34.9 39.9

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 52.3 51.3 53.3

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 2250 2250 2250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 50.9 47.9 53.9

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2750 2750 2750

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 24.4 23.4 25.4

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2750 2600 2900

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 24.4 23.4 25.4

Difference in delivery mm3/st. 5.5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2950 2950 2950

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 4

Oil temperature degC 55 52 58

Remarks
Insert a 1 mm shim between the control lever and the full speed position and measure the injection quantity.

Governor adjustment

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 8.9 6.9 10.9

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 8.9 6.9 10.9

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 150 150 150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 40 30 50

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 150 150 150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 40 30 50

Oil temperature degC 48 46 50

Remarks
IDLE

Speed control lever angle

Pump speed r/min 425 425 425

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 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 72 70.7 73.3

Overflow quantity cm3/min 630 500 760

Oil temperature degC 50 48 52

Remarks
Full

_02

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 330 200 460

Oil temperature degC 48 46 50

Remarks
IDLE

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure kPa 412 392 432

Pressure kgf/cm2 4.2 4 4.4

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Pressure kPa 412 392 432

Pressure kgf/cm2 4.2 4 4.4

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 4.7 4.5 4.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 600 600 600

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 0.5 0.1 1.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 4.7 4.5 4.9

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 6.3 5.9 6.7

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 9 8.7 9.4

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 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 0.9 0.8 1

BCS stroke mm 3.9 3.7 4.1

Control lever angle alpha deg. 20 16 24

Control lever angle beta deg. 40 39 41

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

A:Lever position V:Output voltage C:Lever angle Vi:Applied voltage D:Full speed E:Idle
----------
V1=8.34+-0.03(V) V2=(1.67(V)) C1=40+-1.5(deg) C2=0(deg) V3=10.00(V) V4=10.00(V)
----------
V1=8.34+-0.03(V) V2=(1.67(V)) C1=40+-1.5(deg) C2=0(deg) V3=10.00(V) V4=10.00(V)

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD (perform with W-FICD released) 1. Adjust to obtain L1. 2. Confirm that L2 is obtained when negative pressure P1 (kPa) {P2 (mmHg)} is applied to the actuator. Adjust the stroke using the actuator stroke adjusting screw (F). (A): Pin (B): Actuator shaft (C): Control lever (D): Actuator (E): Lock nut (torque T)
----------
L1=1+1(mm) L2=0.84+-0.1(mm) P1=-53.3(kPa) P2=-400(mmHg)
----------
L1=1+1(mm) L2=0.84+-0.1(mm) T=1.2~1.5(N-m)(0.12~0.15(kgf-m))

0000002001 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the timer stroke Adjust screw (A) so that the timer stroke is the value determined from the graph. 2. Adjustment of the position of the intermediate lever. Insert a shim L between the control lever I and the idle setscrew G. Align the intermediate lever (F) with the aligning line and fix screw intermediate lever's adjusting (E) so that it contacts the control lever. 3. Adjustment of the FICD Insert a shim LT between the control lever I and the idle setscrew G. Use adjusting screw (B) to fix the CSD lever (C) in the position where it operates the intermediate lever via the rod (D). (J) Aligning mark (O) = timer stroke adjustment (mm): TA = -0.041t+2.42 (P) Lever position (deg): theta 1 = -0.108t+4.79 (-20 deg C <= t <= 20 deg C) Theta 2 = -0.133t + 5.29 (20 deg C =< t =< 50 deg C) (Q) Lever position (mm): L1 = -0.035t+1.57 (-20 deg C <= t <= 20 deg C) L2 = -0.044t + 1.75 (20 deg C =< t =< 50 deg C) The (Q) indicates the clearance between the control lever and the idle set screw. X:Temperature t (deg C) Y1:Timer stroke TA (mm) Y2:Control lever position at theta L (deg, mm) (R) Cooling water temperature (deg C) (S) Cooling water temperature: increase direction N:Pump speed (r/min) (M) Timer piston stroke (mm) (K) Lever angle (deg) (Z) Lever position (mm)
----------
L=1.2+-0.05(mm) LT=L+-0.05(mm) N1=500(r/min)
----------
L=1.2+-0.05(mm) LT=L+-0.05(mm) N1=500(r/min) R1=20(degC) R2=-20(degC) M1=1.9+-0.4(mm) M2=3.4+-0.6(mm) K1=3.6+-1(deg) K2=7.9+-3(deg) Z1=1.2+-0.3(mm) Z2=2.6+-1(mm)