104780-9150 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047809150

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104780-9150 1047809150

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Cross reference number

ZEXEL 104780-9150 1047809150

Zexel num

Bosch num

Firm num

Name

104780-9150

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

(Solenoid timer adjustment condition) OFF

Injection timing adjustment

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 49.3 48.8 49.8

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 43.4 40.9 45.9

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 49.3 48.3 50.3

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2000 2000 2000

Average injection quantity mm3/st. 47.1 44.1 50.1

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2550 2550 2550

Average injection quantity mm3/st. 10.9 8.9 12.9

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 37 32 42

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2550 2550 2550

Average injection quantity mm3/st. 10.9 8.4 13.4

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 7.7 5.7 9.7

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 7.7 5.2 10.2

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 45 80

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 45 80

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1100 1100 1100

Overflow quantity cm3/min 390 260 520

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1100 1100 1100

Pressure with S/T ON kPa 520 481 559

Pressure with S/T ON kgf/cm2 5.3 4.9 5.7

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

Remarks
OFF

Stop lever angle_02

Pump speed r/min 1100 1100 1100

Pressure with S/T OFF kPa 432 393 471

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

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_03

Pump speed r/min 1700 1700 1700

Pressure with S/T OFF kPa 559 520 598

Pressure with S/T OFF kgf/cm2 5.7 5.3 6.1

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1100 1100 1100

Timer stroke with S/T ON mm 3.4 3 3.8

Timer stroke with S/T OFF mm 1.9 1.7 2.1

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 850 850 850

Timer stroke with S/T OFF mm 0.5 0 1

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Timer stroke with S/T ON mm 3.4 2.9 3.9

Timer stroke with S/T OFF mm 1.9 1.6 2.2

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_04

Pump speed r/min 1700 1700 1700

Timer stroke with S/T OFF mm 4.4 3.9 4.9

Oil temperature degC 50 48 52

_05

Pump speed r/min 2300 2300 2300

Timer stroke with S/T OFF mm 6.1 5.6 6.5

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 1100 1100 1100

Average injection quantity mm3/st. 34 33.5 34.5

Timer stroke TA mm 1.2 1 1.4

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 1100 1100 1100

Average injection quantity mm3/st. 34 33 35

Timer stroke TA mm 1.2 0.9 1.5

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 1100 1100 1100

Average injection quantity mm3/st. 25 22.5 27.5

Timer stroke TA mm 0.6 0.1 1.1

Timer stroke variation dT mm 1.3 1.3 1.3

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 0.9 0.8 1

Pre-stroke mm 0.1 0.08 0.12

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 36 31 41

Information:

Illustration 1 g00564355
7W-2743 Electronic Speed Switch (ESS)
(1) Push button for Overspeed Verification
(2) Reset button
(3) Overspeed indicator lamp
(4) Seal screw plug for adjusting the engine overspeed
(5) Seal screw plug for adjusting the crank terminate speed
(6) Seal screw plug for adjusting the oil step pressure speed setting The oil step speed calibration increases the oil step speed setting or the oil step speed calibration decreases the oil step speed setting. Refer to the Speed Specification Chart in order to find the oil step speed that is equal to the engine rpm when the engine is running.
Remove the lockwire and the seal from seal screw plug (6). Remove seal screw plug (6) from the access hole for the oil step speed adjusting screw.
Use a small screwdriver to lightly turn the oil step speed adjusting screw in the direction of the "MAX" arrow or the clockwise direction. Turn the screw twenty times. The oil step speed adjusting screw will vary the setting of a potentiometer that is inside of the ESS. The oil step speed adjusting screw will not cause damage to the potentiometer. Also, the screw can not be removed if the screw is turned in the wrong direction.
Connect a voltmeter with the positive lead at terminal (ESS-13) and the negative lead at (ESS-5). Use a 6V-7070 Digital Multimeter or a voltmeter with the same accuracy. Measure the voltage.
For a specific engine rating, find the engine rpm in the column for the oil step speed setting in the Speed Specification Chart. Run the engine at the rpm that is specified in the table.
While the engine is running, look into the hole for the adjustment of the oil step speed. A red indicator lamp should be lighted. A positive voltage should be observed on the multimeter 9 seconds after the indicator lamp is lighted. Turn the oil step speed adjusting screw clockwise until the indicator lamp turns off. The oil step speed setting is above the present rpm of the engine. Slowly turn the oil step speed adjusting screw counterclockwise until the indicator lamp is lighted. After a 9 second delay, a positive voltage should be observed on the multimeter. This position is the correct setting for the oil step speed.
Install seal screw plug (6) in the access hole for the oil step speed adjusting screw. Tighten the screw to a torque of 0.20 0.03 N m (1.8 .3 lb in). Install the lockwire and the seal if the overspeed calibration and the crank terminate speed calibration are also complete.

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