104761-2010 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047612010

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Information injection-pump assembly

ZEXEL 104761-2010 1047612010

Cross reference number

ZEXEL 104761-2010 1047612010

Zexel num

Bosch num

Firm num

Name

104761-2010

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 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 33.6 33.2 34

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 700 700 700

Boost pressure kPa 28 26.7 29.3

Boost pressure mmHg 210 200 220

Average injection quantity mm3/st. 38.6 38.2 39

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 33.6 32.7 34.5

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 700 700 700

Boost pressure kPa 28 26.7 29.3

Boost pressure mmHg 210 200 220

Average injection quantity mm3/st. 38.6 37.7 39.5

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1200 1200 1200

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 46 43.5 48.5

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1800 1800 1800

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 45.7 42.7 48.7

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 2200 2200 2200

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 43.8 40.8 46.8

Oil temperature degC 52 50 54

Injection timing adjustment_08

Pump speed r/min 2300 2300 2300

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 43.5 40 47

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2500 2500 2500

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 20.5 19.5 21.5

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2500 2500 2500

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 20.5 19 22

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2800 2800 2800

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 3

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. 14 13 15

Difference in delivery mm3/st. 1.7

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. 14 12 16

Difference in delivery mm3/st. 2.2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 800 800 800

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5

Oil temperature degC 50 48 52

Boost compensator adjustment

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 30.3 23.8 36.8

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 5.6 5.55 5.65

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 23.9 16.9 30.9

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 5.6 5.55 5.65

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 40 40

Basic *

Oil temperature degC 48 46 50

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 40 40

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

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

Oil temperature degC 50 48 52

Remarks
With an O-ring

Stop lever angle

Pump speed r/min 900 900 900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure with S/T OFF kPa 432 403 461

Pressure with S/T OFF kgf/cm2 4.4 4.1 4.7

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 900 900 900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure with S/T ON kPa 353 304 402

Pressure with S/T ON kgf/cm2 3.6 3.1 4.1

Pressure with S/T OFF kPa 431 392 470

Pressure with S/T OFF kgf/cm2 4.4 4 4.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1200 1200 1200

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure with S/T OFF kPa 490 451 529

Pressure with S/T OFF kgf/cm2 5 4.6 5.4

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2300 2300 2300

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure with S/T OFF kPa 765 726 804

Pressure with S/T OFF kgf/cm2 7.8 7.4 8.2

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 900 900 900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke with S/T OFF mm 3.4 3.2 3.6

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke with S/T ON mm 1.7 1.3 2.1

Timer stroke with S/T OFF mm 3.4 3.1 3.7

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1200 1200 1200

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke with S/T OFF mm 5.2 4.8 5.6

Oil temperature degC 50 48 52

_04

Pump speed r/min 2300 2300 2300

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke with S/T OFF mm 9.8 9.3 10.2

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. 42 37 47

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer 1. Determine the position of the control lever at the adjusting point. Fix with the dummy bolt contacting the lever. 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 V:Output voltage P:Boost pressure A:Adjusting point B:Checking point C:Control lever angle D:Idle lever angle E:Full speed lever angle F:Conversion point G:From idle H:ON-->OFF I:OFF-->ON J:Connecting diagram for the potentiometer K:Output O:Output when (2) and (3) connected. P:When (4) or (6) connected: switch OFF to ON. Q:When (4) or (6) connected: switch ON to OFF.
----------
V1=3.2+-0.03V Vi=10V
----------
N1=600r/min Q1=16.9+-1.0cm3/1,000st V1=3.2+-0.03V V2=(1.96)V V3=(8.96)V C1=-deg C2=0deg C3=42deg Vi=10V P1=0kPa P2=0mmHg C4=(1.9)deg?@ C5=(22.5++)deg G1=-V G2=-V

0000001901 M-CSD ADJUSTMENT

M-CSD adjustment 1. CSD adjustment Turn the lever (D) clockwise and adjust screw (B) so that the timer piston advance angle is a (L1). Then fix using the nut. 2. With intermediate lever screw (C)'s fixing lever (D) positioned as in 1., pull the intermediate lever in direction X. After confirming that it contacts the stop position, adjust so that screw (C) contacts lever (D) and then fix using the nut. (Intermediate lever status in 2.: full speed, indicates timer's a advance. Confirm that the timer piston advances to b deg when the intermediate lever is returned. 3. Fast idle adjustment Pull the intermediate lever in direction x to contact the stopper and adjust the screw (A) so that the gap between the idle set bracket and the idle screw is L2. Fix using the nut. The gap between the control lever at the idle position and the screw (A) must be L3. (E) control lever (F) intermediate lever
----------
a=3deg b=0deg L1=2.5mm L2=6+-0.05mm L3=(1.7mm)
----------
T1=6~9N-m(0.6~0.9kgf-m) T2=5~7N-m(0.5~0.7kgf-m) L2=6+-0.05mm

0000002001 DASHPOT ADJUSTMENT

Adjustment of the dash pot 1. Insert a block gauge L (thickness gauge) between the idle set bracket and the idle screw. 2. In the above condition, adjust so that the dashpot adjusting screw (A) contacts the pushrod. Then, fix using the nut. Record the dashpot return time t. a = alpha
----------
L=3.8+-0.05mm t=1.8+-0.5sec
----------
T=5.0~7.0N-m(0.5~0.7kgf-m) b=7.4deg L=3.8+-0.05mm(750r/min)