104701-2003 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047012003


104701-2003 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 104701-2003 1047012003

Cross reference number

ZEXEL 104701-2003 1047012003


Zexel num
Bosch num
Firm num
Name
104701-2003 
 
   
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
Governor adjustment
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Pump chamber pressure kPa   617.5 588 647
Pump chamber pressure kgf/cm2   6.3 6 6.6
Basic   *
Governor adjustment_02
Pump speed r/min   100 100 100
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Pump chamber pressure kPa   294 294
Pump chamber pressure kgf/cm2   3 3
Governor adjustment_03
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Pump chamber pressure kPa   618 579 657
Pump chamber pressure kgf/cm2   6.3 5.9 6.7
Governor adjustment_04
Pump speed r/min   2000 2000 2000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Pump chamber pressure kPa   755 706 804
Pump chamber pressure kgf/cm2   7.7 7.2 8.2
Boost compensator adjustment
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   70 70 70
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   4.1 3.9 4.3
Basic   *
Boost compensator adjustment_02
Pump speed r/min   500 500 500
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   7.4 5.4 9.4
Boost compensator adjustment_03
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   8.1 6.1 10.1
Boost compensator adjustment_04
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   70 70 70
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   4.1 3.8 4.4
Boost compensator adjustment_05
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   0 0 0
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   0 0 0
Boost compensator adjustment_06
Pump speed r/min   1500 1500 1500
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Timer stroke mm   9.75 9.3 10.2
Speed control lever angle
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Overflow quantity cm3/min   600 470 730
0000000901
Pump speed r/min   1000 1000 1000
U alpha soll + dU alpha soll V   2.8 2.8 2.8
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   80.5 80 81
Difference in delivery mm3/st.   5
Basic   *
_02
Pump speed r/min   375 375 375
U alpha soll + dU alpha soll V   1.89 1.89 1.89
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   7 4 10
Difference in delivery mm3/st.   2
Basic   *
Remarks
Confirmation of difference in delivery
 
_03
Pump speed r/min   2500 2500 2500
U alpha soll + dU alpha soll V   1.66 1.66 1.66
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   16.1 13.6 18.6
Difference in delivery mm3/st.   5
Basic   *
Remarks
Confirmation of difference in delivery
 
_04
Pump speed r/min   100 100 100
U alpha soll + dU alpha soll V   3.5 3.5 3.5
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   83.3 73.3 93.3
_05
Pump speed r/min   375 375 375
U alpha soll + dU alpha soll V   1.89 1.89 1.89
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   7 4 10
_06
Pump speed r/min   500 500 500
U alpha soll + dU alpha soll V   2.49 2.49 2.49
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   50.1 48.1 52.1
_07
Pump speed r/min   800 800 800
U alpha soll + dU alpha soll V   1.86 1.86 1.86
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   15.4 13.4 17.4
_08
Pump speed r/min   800 800 800
U alpha soll + dU alpha soll V   2.62 2.62 2.62
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   64.4 62.4 66.4
_09
Pump speed r/min   1000 1000 1000
U alpha soll + dU alpha soll V   1.85 1.85 1.85
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   16.6 14.6 18.6
_10
Pump speed r/min   1000 1000 1000
U alpha soll + dU alpha soll V   2.8 2.8 2.8
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   80.5 79.5 81.5
_11
Pump speed r/min   2000 2000 2000
U alpha soll + dU alpha soll V   2.58 2.58 2.58
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   63.7 61.7 65.7
_12
Pump speed r/min   2250 2250 2250
U alpha soll + dU alpha soll V   2.43 2.43 2.43
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   54.3 51.8 56.8
_13
Pump speed r/min   2500 2500 2500
U alpha soll + dU alpha soll V   1.66 1.66 1.66
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   16.1 13.6 18.6
_14
Pump speed r/min   2500 2500 2500
U alpha soll + dU alpha soll V   1 1 1
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   3
Stop lever angle
Pump speed r/min   375 375 375
U alpha soll + dU alpha soll V   1.89 1.89 1.89
TCV duty (%) F TCV 60Hz %   0 0 0
Average injection quantity cm3/min   0 0 0
Stop lever angle_02
Pump speed r/min   2250 2250 2250
U alpha soll + dU alpha soll V   2.43 2.43 2.43
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity cm3/min   0 0 0
0000001101
Pump speed r/min   200 200 200
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.7 2.7 2.7
Speed output
N=Measure the actual speed.
r/min   N+-8
0000001201
Pump speed r/min   1000 1000 1000
TCV duty (%) F TCV 60Hz %   100 100 100
U alpha soll V   2.8 2.8 2.8
Temperature output
Measure T = actual output temperature
degC   T+-5
0000001301
Max. applied voltage V   8 8 8
Test voltage V   13 12 14
0000001401
K dimension mm   3.3 3.2 3.4
KF dimension mm   5.62 5.52 5.72
Pre-stroke mm   0.1 0.08 0.12

Test data Ex:

Injection timing adjustment Comp. resistor/voltage

Test data 104701-2003
Compensation resistance/compensation voltage comparison A = Compensation resistor number B= Compensation resistance C = Compensation voltage delta U alpha soll
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0000001601 HARNESS & CONNECTOR

Test data 104701-2003
Corrugated tube assembly specification (1)Maintain the corrugated tube so that the dimension of the end of the connector and the end of the corrugated are as shown in the figure. (2)At K, pull the Q adjustment resistor towards the clip. (3)Wrap black vinyl tape 4 times around the end of the corrugated tube to fix the tube. A:RS03M-GY B:RS08M-GY C:RS08M-B D:Q adjustment resistor E:Corrugated tube J:PVC tape
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L1=50+-10mm L2=40+-10mm L3=50+-10mm

0000001701 HARNESS & CONNECTOR

Test data 104701-2003
Injection quantity adjustment compensation resistor assembly standards (1)Fix the injection quantity adjustment compensation resistor (Q adjustment resistor) using clips. (2)After fixing the corrugated tube, and with the corrugated tube's end and the end of the Q adjustment resistor aligned, fix the Q adjustment resistor so that it is positioned in the direction shown by the arrow in the figure (each connector clip side). (3)Fix the Q adjustment harness's protective tube to the corrugated tube using black PVC tape. (4)After confirming that the Q adjustment resistor is fixed in the position as shown by the arrow in diagram, cut off the excess clip to leave L2. A:End of corrugated tube B:Injection quantity adjustment compensation resistor (Q adjustment resistor) C:After attaching the clip to the Q adjustment resistor, fix the corrugated tube. D:Q adjustment resistor harness protective tube E:PVC tape K:Figure shown by arrow
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L1=(90mm) L2=(10mm)




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