104740-2204 ZEXEL 9 460 610 514 BOSCH INJECTION-PUMP ASSEMBLY 9460610514 1047402204

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 610 514 9460610514

ZEXEL 104740-2204 1047402204

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Cross reference number

BOSCH 9 460 610 514 9460610514

ZEXEL 104740-2204 1047402204

Zexel num

Bosch num

Firm num

Name

104740-2204
104740-2205

9 460 610 514

INJECTION-PUMP ASSEMBLY
* K

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

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 *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 32.3 29.8 34.8

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 31.9 29.4 34.4

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 36.6 35.6 37.6

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 37.5 35 40

Oil temperature degC 50 48 52

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 *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2400 2400 2400

Average injection quantity mm3/st. 37.1 34.1 40.1

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10.5 9.5 11.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10.5 8.5 12.5

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 5

Oil temperature degC 50 48 52

Boost compensator adjustment

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 18 11.5 24.5

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 5.9 5.9 5.9

Remarks
From idle

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 14.2 7.2 21.2

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 5.9 5.9 5.9

Remarks
From idle

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 50 70

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 400 400 400

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 1000 1000 1000

Overflow quantity cm3/min 390 260 520

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1000 1000 1000

Pressure kPa 412 383 441

Pressure kgf/cm2 4.2 3.9 4.5

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Pressure kPa 412.5 375 450

Pressure kgf/cm2 4.2 3.8 4.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Pressure kPa 588.5 549 628

Pressure kgf/cm2 6 5.6 6.4

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2400 2400 2400

Pressure kPa 735.5 686 785

Pressure kgf/cm2 7.5 7 8

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1000 1000 1000

Timer stroke mm 3.1 2.9 3.3

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 1000 1000

Timer stroke mm 3.1 2.8 3.4

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1800 1800 1800

Timer stroke mm 6.8 6.3 7.3

Oil temperature degC 50 48 52

_04

Pump speed r/min 2400 2400 2400

Timer stroke mm 8.55 8.1 9

Oil temperature degC 52 50 54

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

Test data Ex:

0000001801 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 theta (deg C) Y1:Timer stroke TA (mm) Y2:Control lever L dimension (mm; control lever position) J:TA-theta line theta (deg C) <= 10: TA = 1.23 10 <= theta (deg C) <= 20: TA = -0.012 theta + 1.35 20 <= theta (deg C) <= 53.6: TA = -0.0330 theta + 1.77 K:L-theta graph theta (deg C) <= 10: L = 3.9 10 <= theta (deg C) <= 20: L = -0.04 theta + 4.3 20 <= theta (deg C) <= 52.3: L = -0.108 theta + 5.66
----------
L1=3.5+-0.05mm L2=5.3+-0.05mm L3=3.5mm L4=5.3mm L5=L1+-0.05mm a=30degC
----------
L1=3.5+-0.05mm L4=5.3mm

0000001901 IDLING SWITCH ADJUSTMENT

Idle switch adjustment ON - OFF changeover point: from idle to a (shim thickness L) Idle-c: ON d ~ full speed: OFF (A) = idle lever position (B) = idle switch (potentiometer)
----------
a=5deg+-1deg c=5deg d=5deg L=3.3+-0.05mm
----------
a=5deg+-1deg b=(25deg+-2deg) L=3.3+-0.05mm SW=SW10mm T=6~9N-m{0.6~0.9kgf-m}

Information:

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Turn the crankshaft until the "C" mark on the crankshaft gear is in alignment with the "C" mark on the camshaft gear. To keep the engine timing correct during removal and installation of the camshaft, put a mark on the teeth of the fuel injection pump drive gear and idler gear at location (A). Put a mark on the teeth of the idler gear and camshaft gear at location (B). When installing the camshaft, the engine timing will be correct when the marks at locations (A) and (B) are in alignment and the "C" marks on the crankshaft and camshaft gears are in alignment.2. Remove the bolts, lock and washer (1) that hold the camshaft in position.
Do not cause damage to the lobes or bearings when the camshaft is removed.
3. Remove the camshaft and gear (2).4. If necessary, remove the bolts and gear. The following steps are for the installation of the camshaft.5. Put the camshaft drive gear in position on the end of the camshaft, and install the bolts that hold it. Tighten the bolts to a torque of 55 7 N m (41 5 lb ft).
Do not cause damage to the lobes or bearings when the camshaft is installed.
6. Put 2P2506 Thread Lubricant on the camshaft lobes only, and clean engine oil on the bearing journals. Install camshaft (3) aligning the "C" marks and the marks put on the gears during removal.7. Install washer (1), the lock and bolts.End By:a. install valve liftersb. install timing gear cover
Perform Scheduled Oil Sampling on oil wetted compartments after performing service work to check for contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.