104760-2561 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047602561

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104760-2561 1047602561

Cross reference number

ZEXEL 104760-2561 1047602561

Zexel num

Bosch num

Firm num

Name

104760-2561

INJECTION-PUMP ASSEMBLY
11CK VE6 VE

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

(Solenoid timer adjustment condition)
ON ON

Injection timing adjustment

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 31 30.6 31.4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 30.9 28.9 32.9

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 31 30 32

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 30.9 28.9 32.9

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 32 29.5 34.5

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 32.9 29.9 35.9

Oil temperature degC 52 50 54

Injection timing adjustment_07

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 32.9 29.4 36.4

Oil temperature degC 55 52 58

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 *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 27 24.5 29.5

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. 6.5

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 11 10 12

Difference in delivery mm3/st. 1.7

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 11 9 13

Difference in delivery mm3/st. 2.4

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 40 40

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 40 40

Oil temperature degC 48 46 50

Speed control lever angle

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

Speed control lever angle_02

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 6

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 900 900 900

Overflow quantity with S/T ON cm3/min 390 260 520

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 900 900 900

Pressure with S/T ON kPa 373 344 402

Pressure with S/T ON kgf/cm2 3.8 3.5 4.1

Pressure with S/T OFF kPa 304 255 353

Pressure with S/T OFF kgf/cm2 3.1 2.6 3.6

Basic *

Oil temperature degC 50 48 52

Remarks
ON

Stop lever angle_02

Pump speed r/min 900 900 900

Pressure kPa 372.5 333 412

Pressure kgf/cm2 3.8 3.4 4.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Pressure kPa 559 520 598

Pressure kgf/cm2 5.7 5.3 6.1

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2500 2500 2500

Pressure kPa 716 677 755

Pressure kgf/cm2 7.3 6.9 7.7

Oil temperature degC 55 52 58

0000001101

Pump speed r/min 900 900 900

Timer stroke with S/T ON mm 4.6 4.4 4.8

Timer stroke with S/T OFF mm 2.9 2.5 3.3

Basic *

Oil temperature degC 50 48 52

Remarks
ON

_02

Pump speed r/min 900 900 900

Timer stroke with S/T ON mm 4.6 4.3 4.9

Timer stroke with S/T OFF mm 2.9 2.4 3.4

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1200 1200 1200

Timer stroke with S/T ON mm 6.1 5.6 6.6

Oil temperature degC 50 48 52

_04

Pump speed r/min 1800 1800 1800

Timer stroke with S/T ON mm 9.1 8.4 9.8

Oil temperature degC 50 48 52

_05

Pump speed r/min 2300 2300 2300

Timer stroke with S/T ON mm 11.05 10.6 11.5

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 7.22 7.12 7.32

MS dimension mm 1.8 1.7 1.9

Control lever angle alpha deg. 23 19 27

Control lever angle beta deg. 41 36 46

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Adjusting method (dummy bolt method) 1. Position the control lever at the adjusting points in the table, hold the dummy bolt against the lever and fix. 2. In the fixed position, install the potentiometer so that the output voltage is V1 (supply voltage Vi). 3. After completing potentiometer installation, remove the dummy bolt. N:Pump speed Q:Injection quantity Vo:Output voltage A:Standard point B:Checking point C/L: control lever angle I:Idle position F:Full speed position D:Standards for the potentiometer's ON - OFF switch O:Conversion point O1:OFF-->ON O2:OFF-->ON C:Lever opening (from idle) J:Connecting diagram for the potentiometer K:Output P:Output when (2) and (3) connected. Q:When (4) or (6) connected: switch OFF to ON. R:When (4) or (5) connected: switch ON to OFF.
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V1=3.2+-0.03(V) Vi=10(V)
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N1=600(r/min) Q1=16.9+-1.0(mm3/st) V1=3.2+-0.03(V) V2=0.5++(V) V3=9.6--(V) a=(9.3(deg)) b=0(deg) c=(41(deg)) Vi=10(V) C1=(4.0+-2.5(deg)) C2=(22.5++(deg))

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD Adjust screw (A) so that the timer stroke is as determined from the graph and the formula. Formula t (deg C) <= 10 TA = 2.05 10<= t (deg C) <= 20 TA = -0.019t+2.24 20 < t (deg C) <= 55 TA = -0.0531t + 2.922 X:Temperature t (deg C) Y:Timer stroke TA B:Timer stroke graph
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0000002001 DASHPOT ADJUSTMENT

(1)Adjustment of the dash pot 1. Insert a block gauge L1 between the idle set screw (C) and the bracket (D). 2. In the above condition, adjust the locknut (B) so that the dashpot adjusting (A) contacts the pushrod, and then fix the locknut (Tightening torque T). 3.The dashpot and control lever contact faces must be smooth. Confirm that the control lever returns to the idle position. (2)ISC actuator installation In the idle position, fix the actuator bracket (F) so that the clearance between the control lever and the ISC lever roller (E) is L2.
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L1=2.7+-0.05(mm) L2=1.0+1.0-0.5(mm) T=6~9(N-m)(0.6~0.9(kgf-m))
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L1=2.7+-0.05(mm) L2=1.0+1.0-0.5(mm)