104749-5381 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047495381


104749-5381 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 104749-5381 1047495381

Cross reference number

ZEXEL 104749-5381 1047495381


Zexel num
Bosch num
Firm num
Name
104749-5381 
 
   
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   750 750 750
Boost pressure kPa   32 30.7 33.3
Boost pressure mmHg   240 230 250
Average injection quantity mm3/st.   46.9 46.4 47.4
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   32 30.7 33.3
Boost pressure mmHg   240 230 250
Average injection quantity mm3/st.   46.9 45.9 47.9
Difference in delivery mm3/st.   3.5
Basic   *
Oil temperature degC   50 48 52
Injection timing adjustment_05
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_06
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_07
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   2650 2650 2650
Boost pressure kPa   72 70.7 73.3
Boost pressure mmHg   540 530 550
Average injection quantity mm3/st.   24.4 21.4 27.4
Difference in delivery mm3/st.   5.5
Basic   *
Oil temperature degC   55 52 58
Injection quantity adjustment_02
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
Injection quantity adjustment_03
Pump speed r/min   2650 2650 2650
Boost pressure kPa   72 70.7 73.3
Boost pressure mmHg   540 530 550
Average injection quantity mm3/st.   24.4 21.4 27.4
Difference in delivery mm3/st.   5.5
Oil temperature degC   55 52 58
Governor adjustment
Pump speed r/min   375 375 375
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   375 375 375
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.   35 25 45
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.   35 25 45
Oil temperature degC   48 46 50
Remarks
IDLE
 
Speed control lever angle
Pump speed r/min   375 375 375
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   540 530 550
Overflow quantity cm3/min   630 500 760
Oil temperature degC   50 48 52
Remarks
Full
 
_02
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Overflow quantity cm3/min   380 250 510
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
Control lever angle alpha deg.   20 16 24
Control lever angle beta deg.   45 40 50

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Test data 104749-5381
Adjusting method (applied voltage Vi, dummy bolt method) 1. Hold the dummy bolt against the control lever when N=N1, Q=Q1. Fix using the locknut. 2. When adjusting the potentiometer, position the control lever against the dummy bolt and adjust the potentiometer so that the output voltage is V1. 3. After completing adjustment remove the dummy bolt. Confirm that the potentiometer output voltage is as specified above at the control lever idle position and full position. N:Pump speed V:Output voltage Q:Injection quantity P:Boost pressure A:Adjusting point B:Checking point R:Lever position R1:Idle R2:Full speed (C) Nut 013020-6040 (D) Dummy bolt 146526-3300
----------
N1=1000r/min V1=4.76+-0.03V Q1=28.8+-1.0cm3/1,000st Vi=10V
----------
N1=1000r/min V1=4.76+-0.03V V2=(1.06+-0.45)V V3=(8.38+-0.65)V Q1=28.8+-1.0cm3/1,000st

0000001901 V-FICD ADJUSTMENT

Test data 104749-5381
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+1mm L2=1.32+-0.1mm P1=-53.3kPa P2=-400mmHg
----------
L1=1+1mm L2=1.32+-0.1mm T=1.2~1.5N-m{0.12~0.15kgf-m}

0000002001 W-CSD ADJUSTMENT

Test data 104749-5381
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+-0.05mm LT=L+-0.05mm
----------
L=1.2+-0.05mm N1=500r/min R1=20degC R2=-20degC M1=1.9+-0.4mm M2=3.4+-0.6mm K1=3.6+-1deg K2=7.9+-3deg Z1=1.2+-0.3mm Z2=2.6+-1mm

0000002101 DASHPOT ADJUSTMENT

Test data 104749-5381
Adjustment of the dash pot 1. Hold the position of the control lever (A) at a (gap L). 2. In the above condition, adjust the position of the dash pot so that the tip end of the dash pot (B) contacts the control lever (A) and fix with the nut (C). TT
----------
L=5.2-0.5mm T=6~9N-m(0.6~0.9Kgf-m) a=15.8-1.5deg
----------
L=5.2-0.5mm




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