104740-2393 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047402393

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104740-2393 1047402393

Cross reference number

ZEXEL 104740-2393 1047402393

Zexel num

Bosch num

Firm num

Name

104740-2393

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)
Left L

(Solenoid timer adjustment condition)
Excluding timer, pump chamber pressure ON

Injection timing adjustment

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 36.6 36.2 37

Difference in delivery mm3/st. 3

Basic *

Injection timing adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 14 11.5 16.5

Injection timing adjustment_03

Pump speed r/min 2400 2400 2400

Average injection quantity mm3/st. 36.1 32.6 39.6

Injection timing adjustment_04

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 37.3 34.8 39.8

Injection timing adjustment_05

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 36.6 35.7 37.5

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 32.6 29.6 35.6

Injection timing adjustment_07

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 33.3 30.8 35.8

Injection timing adjustment_08

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 35.1 29.6 40.6

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 14 12 16

Difference in delivery mm3/st. 4.5

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. 10.5 9.5 11.5

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 5

Governor adjustment_03

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10.5 9 12

Boost compensator adjustment

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 20.5 14 27

Remarks
From idle

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 15.2 8.2 22.2

Remarks
From idle

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 50 70

Basic *

Remarks
Full

Speed control lever angle

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1000 1000 1000

Overflow quantity cm3/min 438 306 570

Stop lever angle

Pump speed r/min 1000 1000 1000

Pressure with S/T ON kPa 421.5 392 451

Pressure with S/T ON kgf/cm2 4.3 4 4.6

Pressure with S/T OFF kPa 324 275 373

Pressure with S/T OFF kgf/cm2 3.3 2.8 3.8

Basic *

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Pressure with S/T ON kPa 421.5 392 451

Pressure with S/T ON kgf/cm2 4.3 4 4.6

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Pressure with S/T ON kPa 588.5 559 618

Pressure with S/T ON kgf/cm2 6 5.7 6.3

Stop lever angle_04

Pump speed r/min 2400 2400 2400

Pressure with S/T ON kPa 725.5 686 765

Pressure with S/T ON kgf/cm2 7.4 7 7.8

0000001101

Pump speed r/min 1000 1000 1000

Timer stroke with S/T ON mm 3.1 2.9 3.3

Timer stroke with S/T OFF mm 1.1 0.7 1.5

Basic *

_02

Pump speed r/min 1000 1000 1000

Timer stroke with S/T ON mm 3.1 2.8 3.4

Timer stroke with S/T OFF mm 1.1 0.6 1.6

_03

Pump speed r/min 1800 1800 1800

Timer stroke with S/T ON mm 6.8 6.2 7.4

_04

Pump speed r/min 2400 2400 2400

Timer stroke with S/T ON mm 8.5 8 9

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 6.78 6.68 6.88

MS dimension mm 0.8 0.7 0.9

Control lever angle alpha deg. 25 23 27

Control lever angle beta deg. 42 37 47

Control lever angle gamma deg. 8.7 8.2 9.2

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. Measure the injection quantity at control lever position a (shim thickness = approximately L mm) at N = N1 r/min, determine the voltage using the formula, and adjust the potentiometer. A:Performance standards C:Position of the control lever N:Pump speed Vo:Output voltage E:Conversion formula G:Idle H:Full speed K:Applied voltage X:Injection quantity (cm3/1,000st) Y:Voltage (V) M:Connecting diagram for the potentiometer O:Output P:Output when (2) and (3) connected. R:At target value Q1cm3/1,000 st, set voltage at V3 (V).
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N1=700r/min a=8.7deg L=5.6+-0.05mm Q1=15.1cm3/1,000st V3=4.46V
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N1=700r/min Q1=15.1cm3/1.000st V1=(2.34+-0.75)V V2=9.96++V V3=4.46V K=10V J:V+-0.03=0.06740X+3.4462

0000001901 CONTROL LEVER ANGLE

Control lever angle measurement 1. Measure dimension L between the end of the lever and the flange face. 2. Measure the lever angle from the pin hole R (plate). (A) = pump flange face (B) = lever angle measuring hole Alpha = a beta = b
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R=61mm L=25.7~29.7mm
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R=61mm L=25.7~29.7mm a=23~27deg b=37~47deg

0000002001 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 Fig. 3 (Q). (2)(1) Adjust using the screw (I) so that the timer advance angle determined in item (1) is obtained. 2. Setting the intermediate lever position (refer to fig 1 and fig 2) (1)Insert a block gauge L1 between the idling set screw (H) and the control lever (G). (2)Insert a shim of thickness L2 mm between the intermediate lever (D) and the intermediate lever bracket (E). Ensure the screw (F) contacts the control lever (G), then fix the nut. 3. W-CSD lever adjustment [refer to fig 1 (O) and fig 2 (P)] (1)After completing (2) above, remove the block gauge L3 and the shim with the thickness L4. (2)Insert a block gauge L5 determined from the graph (L-theta) in figure 3 (Q) between the idling set screw (H) and the control lever (G). (3)Adjust the screw (B) until the screw (F) contacts the control lever (G). Then fix locknut (A). Note: The temperature of the wax at adjustment must not exceed a. X:Temperature X (V) Y1:Timer stroke TA (mm) Y2:Control lever L dimension (mm; control lever position) J:Graph TA-X: X (deg C) <= 10: TA = 0.82 10 <= X (deg C) <= 20: TA =-0.027X + 1.09 20 <= X (deg C) < = 40 :TA =-0.0275X + 1.1 K:Graph L-X: X (deg C) <= 10: L = 3.9 10 <= X (deg C) <= 30: L = -0.09X + 4.8 20 <= X (deg C) <= 54.3: L =-0.086X + 4.68
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L1=L=3.0+-0.05mm L2=5.3+-0.05mm L3=3mm L4=5.3mm L5=L+-0.05mm a=30degC
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L4=5.3mm