104760-2492 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047602492

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104760-2492 1047602492

Cross reference number

ZEXEL 104760-2492 1047602492

Zexel num

Bosch num

Firm num

Name

104760-2492

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

Average injection quantity mm3/st. 30.5 30 31

Difference in delivery mm3/st. 2

Basic *

Injection timing adjustment_02

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 27 24.5 29.5

Injection timing adjustment_03

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 30.7 28.6 32.8

Injection timing adjustment_04

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 30.2 28.2 32.2

Injection timing adjustment_05

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 30.6 28.6 32.6

Injection timing adjustment_06

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 30.9 29.4 32.4

Injection timing adjustment_07

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 30.5 29.5 31.5

Injection timing adjustment_08

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 31.3 29.5 33.1

Injection quantity adjustment

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 27 25 29

Difference in delivery mm3/st. 4.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 6.5

Governor adjustment

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 9 8 10

Difference in delivery mm3/st. 1.1

Basic *

Governor adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 3

Governor adjustment_03

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 9 7.5 10.5

Boost compensator adjustment

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 16.9 10.4 23.4

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 40 40

Difference in delivery mm3/st. 15

Basic *

Speed control lever angle

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF at full-load position

Speed control lever angle_02

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 4

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 900 900 900

Overflow quantity cm3/min 390 258 522

Stop lever angle

Pump speed r/min 900 900 900

Pressure kPa 372.5 343 402

Pressure kgf/cm2 3.8 3.5 4.1

Basic *

Stop lever angle_02

Pump speed r/min 900 900 900

Pressure kPa 372.5 343 402

Pressure kgf/cm2 3.8 3.5 4.1

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Pressure kPa 578.5 549 608

Pressure kgf/cm2 5.9 5.6 6.2

Stop lever angle_04

Pump speed r/min 2500 2500 2500

Pressure kPa 745.5 716 775

Pressure kgf/cm2 7.6 7.3 7.9

0000001101

Pump speed r/min 900 900 900

Timer stroke mm 2.3 2.1 2.5

Basic *

_02

Pump speed r/min 900 900 900

Timer stroke mm 2.3 2 2.6

_03

Pump speed r/min 1200 1200 1200

Timer stroke mm 3.8 3.2 4.4

_04

Pump speed r/min 1800 1800 1800

Timer stroke mm 7 6.2 7.8

_05

Pump speed r/min 2300 2300 2300

Timer stroke mm 8.9 8.4 9.4

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 7.24 7.14 7.34

MS dimension mm 1.8 1.7 1.9

Control lever angle alpha deg. 23 19 27

Control lever angle beta deg. 42 37 47

Control lever angle gamma deg. 14.4 13.9 14.9

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer In the following condition, change the installation position of the potentiometer to adjust the output voltage to within the specified values. At N = N1 and control lever position a (corresponding to shim thickness L), measure the injection quantity, calculate the voltage from the graph, and then adjust the potentiometer. A:Performance standards C:Position of the control lever N:Pump speed Vo:Output voltage E:Conversion formula (J) G:Idle H:Full speed K:Applied voltage X:Injection quantity (mm3/st) Y:Voltage (V) M:Connecting diagram for the potentiometer O:Output P:Output when (2) and (3) connected.
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N1=600r/min a=14.4deg L=7.7mm
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V1=1.00+-0.6V V2=7.80+-1.4V J=V+-0.03=0.0592X+-2.394 K=10V

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD Adjust the timer stroke using the screw so that it is as determined from the graph. Caution: The temperature of the wax at adjustment must not exceed a. A:Screw B:Timer stroke graph X:Temperature t Y:Timer stroke TA
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a=30degC
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0000002001 DASHPOT ADJUSTMENT

Adjustment of the dash pot 1. Insert a block gauge L1 (thickness gauge) between the idle set screw (C) and the control lever (D). 2. In the above condition, adjust the position of the dash pot so that the dash pot adjustment screw (A) contacts the push rod and then fix the screw using the nut (B). TT Note: (1)The adjusting screw and pushrod contact faces must be smooth. (2)Confirm that the control lever returns to the idling position. ISC actuator installation 1. Maintain the control lever in the idling position. 2. Fix actuator bracket (F) so that the gap between the control lever and the ISC lever's roller (E) is L2.
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L1=1.8+-0.05mm L2=1.0-0.5+1.0mm T=6~9Nm{0.6~0.9kgfm}
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L1=1.8+-0.05mm L2=1.0-0.5+1.0mm