104769-2000 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047692000

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104769-2000 1047692000

Cross reference number

ZEXEL 104769-2000 1047692000

Zexel num

Bosch num

Firm num

Name

104769-2000

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

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. 31.2 30.7 31.7

Difference in delivery mm3/st. 2.5

Basic *

Injection timing adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 12.6 9.1 16.1

Injection timing adjustment_03

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 31 28 34

Injection timing adjustment_04

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 31.2 30.2 32.2

Injection timing adjustment_05

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 29.5 27.5 31.5

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 12.6 9.6 15.6

Basic *

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 5

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 7.8 6.3 9.3

Difference in delivery mm3/st. 3

Basic *

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 7.8 5.8 9.8

Governor adjustment_03

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 4

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 44.8 40.8 48.8

Basic *

Speed control lever angle

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1200 1200 1200

Overflow quantity with S/T ON cm3/min 402 270 534

Stop lever angle

Pump speed r/min 1200 1200 1200

Pressure with S/T ON kPa 431.5 402 461

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

Basic *

Stop lever angle_02

Pump speed r/min 600 600 600

Pressure with S/T ON kPa 294 255 333

Pressure with S/T ON kgf/cm2 3 2.6 3.4

Stop lever angle_03

Pump speed r/min 1200 1200 1200

Pressure with S/T ON kPa 431.5 392 471

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

Pressure with S/T OFF kPa 343 304 382

Pressure with S/T OFF kgf/cm2 3.5 3.1 3.9

Stop lever angle_04

Pump speed r/min 2300 2300 2300

Pressure with S/T ON kPa 696 657 735

Pressure with S/T ON kgf/cm2 7.1 6.7 7.5

0000001101

Pump speed r/min 1200 1200 1200

Timer stroke with S/T ON mm 4.3 4 4.6

Basic *

_02

Pump speed r/min 800 800 800

Timer stroke with S/T ON mm 2.4 1.8 3

_03

Pump speed r/min 1200 1200 1200

Timer stroke with S/T ON mm 4.3 3.9 4.7

Timer stroke with S/T OFF mm 3 2.6 3.4

_04

Pump speed r/min 2300 2300 2300

Timer stroke with S/T ON mm 8.15 7.7 8.6

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. 3.6 3.1 4.1

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. 3.6 2.1 5.1

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. 24 19 29

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
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N1=1200r/min
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0000001801 STARTING I/Q ADJUSTMENT

Starting injection quantity adjustment Adjust the adjusting bolt A so that the starting injection quantity adjustment is within the standards. Fix using nut (B). (C) = stopper bolt
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0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the advance angle of the timer (1)Determine the timer advance angle from the graph in the figure. (2)(1) Adjust with the screw (A) so that the timer advance angle determined in the item (1) is obtained. 2. Setting the intermediate lever position (1)Insert a block gauge L1 = L between the idling set screw (G) and the stopper (H). (2)When the intermediate lever is perpendicular, fix it so that it contacts the control lever (F). (3)Align lever (D) perpendicular to the aligning mark. 3. W-CSD lever adjustment (1)Insert a block gauge L2 determined from the graph (L-t) in the figure between the idling set screw (G) and the stopper (H). (2)Fix screw (B) so that the W-CSD lever (C)'s roller contacts the intermediate lever (D). Note: When inserting the block gauge, separate lever (C) and (D) using screw (B) to prevent excessive force on the lever. X = temperature t (deg C) Y1 = timer lift TA (mm) Y2 = control lever dimension L mm (control lever position J = graph L - t O = graph TA - t: K = intermediate lever perpendicular position M = aligning mark
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L1=0.95+-0.05mm L2=L1+-0.05mm
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L1=0.95+-0.05mm

0000002001 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
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N1=700r/min a=13.3deg L=6.5mm
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J=Vo=+-0.05=0.08696Q+0.839 Vi=-V