104761-4271 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047614271

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104761-4271 1047614271

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Cross reference number

ZEXEL 104761-4271 1047614271

Zexel num

Bosch num

Firm num

Name

104761-4271

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 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 51 50.5 51.5

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 700 700 700

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Average injection quantity mm3/st. 57.4 56.9 57.9

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 60 59.5 60.5

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 51 50 52

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 700 700 700

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Average injection quantity mm3/st. 57.4 56.4 58.4

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 60 59 61

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 61.6 57.6 65.6

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 1800 1800 1800

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 57.6 53.6 61.6

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 25.9 23.9 27.9

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2500 2500 2500

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2300 2300 2300

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 25.9 23.4 28.4

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 8.7 6.7 10.7

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 8.7 6.2 11.2

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

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. 61.5 51.5 81.5

Basic *

Oil temperature degC 48 46 50

Remarks
Full

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. 61.5 51.5 81.5

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

Speed control lever angle_02

Pump speed r/min 250 250 250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5

Oil temperature degC 48 46 50

Remarks
Magnet OFF at full-load position

0000000901

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Overflow quantity with S/T ON cm3/min 440 310 570

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 53.3 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T ON kPa 549 510 588

Pressure with S/T ON kgf/cm2 5.6 5.2 6

Pressure with S/T OFF kPa 441 412 470

Pressure with S/T OFF kgf/cm2 4.5 4.2 4.8

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 53.3 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T OFF kPa 441 402 480

Pressure with S/T OFF kgf/cm2 4.5 4.1 4.9

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_03

Pump speed r/min 1700 1700 1700

Boost pressure kPa 53.3 53.3 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T OFF kPa 588 549 627

Pressure with S/T OFF kgf/cm2 6 5.6 6.4

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T ON mm 4.6 4.2 5

Timer stroke with S/T OFF mm 3.1 2.9 3.3

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T OFF mm 2 1.5 2.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T ON mm 4.6 4.1 5.1

Timer stroke with S/T OFF mm 3.1 2.8 3.4

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T OFF mm 5.3 4.8 5.8

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T ON mm 7 6.5 7.4

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 47 46.5 47.5

Timer stroke TA mm 2.4 2.2 2.6

Timer stroke variation dT mm 0.7 0.7 0.7

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 47 46 48

Timer stroke TA mm 2.4 2.2 2.6

Timer stroke variation dT mm 0.7 0.7 0.7

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 33 30.5 35.5

Timer stroke TA mm 1.6 1.1 2.1

Timer stroke variation dT mm 1.5 1.5 1.5

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 6.76 6.66 6.86

MS dimension mm 1.3 1.2 1.4

BCS stroke mm 2.8 2.6 3

Pre-stroke mm 0.1 0.08 0.12

Control lever angle alpha deg. 55.5 51.5 59.5

Control lever angle beta deg. 40 35 45

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Potentiometer adjustment 1. Applied voltage: Vi 2. Boost pressure = P1kPa {P2 mmHg} 3. Set the control lever at the adjusting point. Position the dummy bolt against the lever and fix. 4. Assemble the potentiometer to obtain output voltage V1 (V) at the fixed position. 5. After mounting the potentiometer, remove the dummy bolt. N:Pump speed Q:Injection quantity V:Output voltage A:Adjusting point B:Checking point C:Angle of the control lever C1:Idle C2:Full-speed
----------
V1=5.52+-0.03V P1=0kPa P2=0mmHg Vi=10.0V
----------
N1=850r/min Q1=16.5+-1.0cm3/1,000st V1=5.52+-0.03V V2=1.80+-0.6V V3=Above9.97V P1=0kPa P2=0mmHg Vi=10.0V

Information:

Delco-Remy Alternator
(1) Regulator. (2) Roller bearing. (3) Stator winding. (4) Ball bearing. (5) Rectifier bridge. (6) Field winding. (7) Rotor assembly. (8) Fan.Alternator (Bosch)
The alternator is driven by V-belts from the crankshaft pulley. This alternator is a three phase, self-rectifying charging unit. The regulator is part of the alternator.
Bosch Alternator
(1) Fan. (2) Stator winding. (3) Field winding. (4) Regulator. (5) Ball bearing. (6) Roller bearing. (7) Rotor. (8) Rectifier assembly.This alternator design has no need for slip rings or brushes, and the only part that has movement is the rotor assembly. All conductors that carry current are stationary. The conductors are: the field winding, stator windings, six rectifying diodes, and the regulator circuit components.The rotor assembly has many magnetic poles like fingers with air space between each opposite pole. The poles have residual magnetism (like permanent magnets) that produce a small amount of magnet-like lines of force (magnetic field) between the poles. As the rotor assembly begins to turn between the field winding and the stator windings, a small amount of alternating current (AC) is produced in the stator windings from the small magnetic lines of force made by the residual magnetism of the poles. This AC current is changed to direct current (DC) when it passes through the diodes of the rectifier bridge. Most of this current goes to charge the battery and to supply the low amperage circuit, and the remainder is sent to the field windings. The DC current flow through the field windings (wires around an iron core) now increases the strength of the magnetic lines of force. These stronger lines of force now increase the amount of AC current produced in the stator windings. The increased speed of the rotor assembly also increases the current and voltage output of the alternator.The voltage regulator is a solid state (transistor, stationary parts) electronic switch. It feels the voltage in the system and switches on and off many times a second to control the field current (DC current to the field windings) for the alternator to make the needed voltage output.Alternator (Nippondenso)
The alternator is driven by a V-belt from the crankshaft pulley. The only part in the alternator which has movement is rotor assembly (9). Rotor assembly (9) is held in position by a ball bearing at each end of rotor shaft (8).The alternator is made up of a frame (3) on the drive end, rotor assembly (9), stator assembly (5), rectifier assembly (11), brushes (7) and holder assembly, slip rings (13), rear end frame (12) and regulator (6). Drive pulley (1) has a fan (2) for heat removal by the movement of air through the alternator.
Alternator Schematic (With Regulator Attached)
(1) Pulley. (2) Fan. (3) Drive end frame. (4) Stator coils. (5) Stator assembly. (6) Regulator. (7) Brushes. (8) Rotor shaft. (9) Rotor assembly. (10) Field windings. (11) Rectifier assembly. (12) Rear end frame. (13) Slip rings.Rotor assembly (9) has field windings (10) (wires around an iron core) which make magnetic lines of force when direct