104760-2060 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047602060

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104760-2060 1047602060

Cross reference number

ZEXEL 104760-2060 1047602060

Zexel num

Bosch num

Firm num

Name

104760-2060

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

(Note)
For Japan: year/month/day (change sequence) 1983/9/13 (2)

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

(Solenoid timer adjustment condition) ON

Injection timing adjustment

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 31.3 30.8 31.8

Difference in delivery mm3/st. 2.5

Basic *

Injection timing adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 11.7 8.7 14.7

Injection timing adjustment_03

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 29.8 26.8 32.8

Injection timing adjustment_04

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 31.3 30.8 31.8

Injection timing adjustment_05

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 25.7 23.7 27.7

Injection timing adjustment_06

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 30.5 30 31

Difference in delivery mm3/st. 2.5

Basic *

Remarks
For Japan

Injection timing adjustment_07

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 10 6.5 13.5

Remarks
For Japan

Injection timing adjustment_08

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 29.1 26.1 32.1

Remarks
For Japan

Injection timing adjustment_09

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 30.5 29.5 31.5

Remarks
For Japan

Injection timing adjustment_10

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 25.1 23.1 27.1

Remarks
For Japan

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 11.7 8.7 14.7

Basic *

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 5

Injection quantity adjustment_03

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 10 7 13

Basic *

Remarks
For Japan

Injection quantity adjustment_04

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 5

Remarks
For Japan

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8.4 6.9 9.9

Difference in delivery mm3/st. 3

Basic *

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8.6 7.1 10.1

Governor adjustment_03

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 4

Governor adjustment_04

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8.2 6.7 9.7

Difference in delivery mm3/st. 3

Basic *

Remarks
For Japan

Governor adjustment_05

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8.2 6.2 10.2

Remarks
For Japan

Governor adjustment_06

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 4

Remarks
For Japan

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 49.1 44.1 54.1

Basic *

Remarks
Refer to additional devices.

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 47.8 42.8 52.8

Basic *

Remarks
For Japan: refer to additional devices

Speed control lever angle

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

Speed control lever angle_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Remarks
For Japan: Magnet OFF

0000000901

Pump speed r/min 1200 1200 1200

Overflow quantity cm3/min 400 270 530

_02

Pump speed r/min 1200 1200 1200

Overflow quantity cm3/min 400 270 530

Remarks
For Japan

Stop lever angle

Pump speed r/min 1800 1800 1800

Pressure with S/T ON kPa 608 579 637

Pressure with S/T ON kgf/cm2 6.2 5.9 6.5

Basic *

Stop lever angle_02

Pump speed r/min 800 800 800

Pressure with S/T ON kPa 382.5 353 412

Pressure with S/T ON kgf/cm2 3.9 3.6 4.2

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Pressure with S/T ON kPa 608 579 637

Pressure with S/T ON kgf/cm2 6.2 5.9 6.5

Pressure with S/T OFF kPa 539.5 510 569

Pressure with S/T OFF kgf/cm2 5.5 5.2 5.8

Stop lever angle_04

Pump speed r/min 2500 2500 2500

Pressure with S/T ON kPa 755.5 726 785

Pressure with S/T ON kgf/cm2 7.7 7.4 8

Stop lever angle_05

Pump speed r/min 1800 1800 1800

Pressure with S/T ON kPa 588.5 559 618

Pressure with S/T ON kgf/cm2 6 5.7 6.3

Basic *

Remarks
For Japan

Stop lever angle_06

Pump speed r/min 800 800 800

Pressure with S/T ON kPa 363 324 402

Pressure with S/T ON kgf/cm2 3.7 3.3 4.1

Remarks
For Japan

Stop lever angle_07

Pump speed r/min 1800 1800 1800

Pressure with S/T ON kPa 588.5 549 628

Pressure with S/T ON kgf/cm2 6 5.6 6.4

Pressure with S/T OFF kPa 520 481 559

Pressure with S/T OFF kgf/cm2 5.3 4.9 5.7

Remarks
For Japan

Stop lever angle_08

Pump speed r/min 2500 2500 2500

Pressure with S/T ON kPa 735.5 696 775

Pressure with S/T ON kgf/cm2 7.5 7.1 7.9

Remarks
For Japan

0000001101

Pump speed r/min 1200 1200 1200

Timer stroke with S/T ON mm 3.8 3.5 4.1

Basic *

_02

Pump speed r/min 1200 1200 1200

Timer stroke with S/T ON mm 3.8 3.5 4.1

Timer stroke with S/T OFF mm 3.1 2.8 3.4

_03

Pump speed r/min 1800 1800 1800

Timer stroke with S/T ON mm 5.9 5.3 6.5

_04

Pump speed r/min 2500 2500 2500

Timer stroke with S/T ON mm 7.35 6.9 7.8

_05

Pump speed r/min 1200 1200 1200

Timer stroke with S/T ON mm 3.7 3.4 4

Basic *

Remarks
For Japan

_06

Pump speed r/min 1200 1200 1200

Timer stroke with S/T ON mm 3.7 3.3 4.1

Timer stroke with S/T OFF mm 3 2.6 3.4

Remarks
For Japan

_07

Pump speed r/min 1800 1800 1800

Timer stroke with S/T ON mm 5.8 5.2 6.4

Remarks
For Japan

_08

Pump speed r/min 2500 2500 2500

Timer stroke with S/T ON mm 7.35 6.9 7.8

Remarks
For Japan

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 -18.7 -18.7

Atmospheric pressure difference mmHg -140 -140 -140

Decrease qty mm3/st. 4.5 4 5

Basic *

_02

Pump speed r/min 1200 1200 1200

Atmospheric pressure difference kPa -18.7 -18.7 -18.7

Atmospheric pressure difference mmHg -140 -140 -140

Decrease qty mm3/st. 4.5 3 6

_03

Pump speed r/min 1200 1200 1200

Atmospheric pressure difference kPa -18.7 -18.7 -18.7

Atmospheric pressure difference mmHg -140 -140 -140

Decrease qty mm3/st. 4.5 4 5

Basic *

Remarks
For Japan

_04

Pump speed r/min 1200 1200 1200

Atmospheric pressure difference kPa -18.7 -18.7 -18.7

Atmospheric pressure difference mmHg -140 -140 -140

Decrease qty mm3/st. 4.5 3 6

Remarks
For Japan

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 6.64 6.54 6.74

MS dimension mm 1.8 1.7 1.9

Control lever angle alpha deg. 23 19 27

Control lever angle beta deg. 44 39 49

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 (1)Assemble the ACS cover, bellows and adjusting shim. (2)At pump speed N1, adjust using a shim to obtain the decrease for the altitude shown in the table. X1 = atmospheric pressure X2 = altitude Y = decrease quantity (A) = adjustment value (B) = test value
----------
N1=1200r/min
----------

0000001801 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Fixing the control lever's starting injection quantity adjusting bolt Adjust the bolt so that the starting injection quantity is within the adjustment values, then fix. 2. Fixing the CSD lever stopper At roller holder advance angle a adjust the lever shaft ball pin so that it contacts the roller holder. At this time, fix the stopper so that the distance from the CSD lever is L1. 3. Fixing the wire CSD lever Fix the wire at the CSD lever position for timer lift determined from the graph. 4. FICD lever screw adjustment After fixing the W-CSD lever, move the control lever from the idle position to position L3 (see figure). In this position, fix the screw so that the clearance between the control lever and the screw is L as determined from the graph. Caution: After fixing the screw, the distance must be L2 or more when the control lever and the head of the screw contact at position b. If not L2 or more, replace the screw with a shorter one (select part no. 146620-1400 or 146620-2800). A = adjusting bolt B = stop lever C = CSD lever D = stopper E = lock screw F = lock bolt G = wire H = control lever I = screw J = FICD lever Y1 = timer lift TA (tolerance+-0.1) Y2 = distance L (tolerance +-0.2) X = wax temperature t (room temperature)
----------
L1=0.5+2mm L2=0.2mm L3=3.2mm a=0deg
----------
L1=0.5+2mm L3=3.2mm

0000001901 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
----------
N1=700r/min a=-deg L=8.6mm
----------
J=- (V) Vi=10V