104740-2281 ZEXEL 9 460 611 168 BOSCH INJECTION-PUMP ASSEMBLY 9460611168 1047402281

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Information injection-pump assembly

BOSCH 9 460 611 168 9460611168

ZEXEL 104740-2281 1047402281

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Components :

0.	INJECTION-PUMP ASSEMBLY	104740-2281
1.	_
2.	FUEL INJECTION PUMP	104640-2281
3.	NUMBER PLATE	146912-2500
4.	_	146672-1120
5.	CAPSULE
6.	ADJUSTING DEVICE
7.	NOZZLE AND HOLDER ASSY	105141-2851
8.	Nozzle and Holder	16600-59Y25
9.	Open Pre:MPa(Kqf/cm2)	12.7{130}
10.	NOZZLE-HOLDER	105071-1361
11.	NOZZLE	105000-2200

Scheme ###:

1/6.	[1]	146601-0900	PACKING RING
6.	[1]	146100-0320	SUPPLY PUMP
9.	[1]	146103-0100	COVER
10.	[2]	139104-0000	FLAT-HEAD SCREW
12.	[1]	146200-0620	DRIVE SHAFT
12/1.	[1]	146200-0000	DRIVE SHAFT
12/2.	[1]	146201-0000	WOODRUFF KEY
12/3.	[2]	146202-0100	DAMPER
12/4.	[1]	146203-0000	TOOTHED GEAR
17.	[1]	146204-0000	PLAIN WASHER
20.	[1]	146210-3220	ROLLER SET
24.	[1]	146303-0000	BEARING PIN
25.	[1]	146304-0000	BEARING PIN
26.	[1]	146305-0000	CLAMPING BAND
27.	[1]	146205-0000	SLOTTED WASHER
29.	[1]	146220-2220	CAM PLATE
30.	[1]	146600-0800	O-RING
31.	[1]	146311-7020	PUMP PLUNGER
32.	[1]	146301-0000	SLIDING PIECE
34.	[1]	146312-2600	COMPRESSION SPRING
34B.	[1]	146312-2500	COMPRESSION SPRING
35/1.	[1]	146690-3200	SHIM D11.5&9.4T0.1
35/1.	[1]	146690-3300	SHIM D11.5&9.4T0.2
35/1.	[1]	146690-3400	SHIM D11.5&9.4T0.25
35/1.	[1]	146690-3500	SHIM D11.5&9.4T1.0
35/1.	[1]	146690-4100	SHIM D11.5&9.4T2
35/1.	[1]	146690-4200	SHIM D11.5&9.4T0.5
35/1.	[1]	146690-4300	SHIM D11.5&9.4T0.75
36.	[1]	146600-0800	O-RING
37.	[1]	146310-1600	COVER
38.	[2]	146620-5000	BLEEDER SCREW
39.	[1]	146310-0100	COVER
40.	[2]	146620-5000	BLEEDER SCREW
41.	[1]	146312-3300	COMPRESSION SPRING
42.	[1]	146602-8500	PLAIN WASHER
43.	[1]	146230-0000	SHIM
44.	[1]	146230-0100	PLAIN WASHER
45.	[1]	146231-0001	SLOTTED WASHER
47.	[2]	146233-0000	SLOTTED WASHER
48/1.	[1]	146603-0000	SHIM D17.0&5.2T0.50
48/1.	[1]	146603-0100	SHIM D17.0&5.2T0.80
48/1.	[1]	146603-0200	SHIM D17.0&5.2T1.00
48/1.	[1]	146603-0300	SHIM D17.0&5.2T1.20
48/1.	[1]	146603-0400	SHIM D17.0&5.2T1.50
48/1.	[1]	146603-0500	SHIM D17.0&5.2T1.80
48/1.	[1]	146603-0600	SHIM D17.0&5.2T2.00
48/1.	[1]	146690-1400	SHIM D17&5.2T0.9
48/1.	[1]	146690-1500	SHIM D17&5.2T1.1
48/1.	[1]	146690-1600	SHIM D17&5.2T1.3
48/1.	[1]	146690-1700	SHIM D17&5.2T1.4
48/1.	[1]	146690-1800	SHIM D17&5.2T1.6
48/1.	[1]	146690-1900	SHIM D17&5.2T1.7
48/1.	[1]	146690-5800	SHIM
48/1.	[1]	146690-5900	SHIM
48/1.	[1]	146690-6000	SHIM
48/1.	[1]	146690-6100	SHIM
48/1.	[1]	146690-6200	SHIM
48/1.	[1]	146690-6300	SHIM
48/1.	[1]	146690-6400	SHIM
48/1.	[1]	146690-6500	SHIM
48/1.	[1]	146690-6600	SHIM
48/1.	[1]	146690-6700	SHIM
48/1.	[1]	146690-6800	SHIM
48/1.	[1]	146690-6900	SHIM
48/1.	[1]	146690-7000	SHIM
48/1.	[1]	146690-7100	SHIM
48/1.	[1]	146690-7200	SHIM
48/1.	[1]	146690-7300	SHIM
48/1.	[1]	146690-7400	SHIM
48/1.	[1]	146690-7500	SHIM
48/1.	[1]	146690-7800	SHIM
49.	[2]	146234-0120	GUIDE PIN
50.	[1]	146403-3120	HYDRAULIC HEAD
50.	[1]	146403-3120	HYDRAULIC HEAD
50.	[1]	146403-3120	HYDRAULIC HEAD
51.	[1]	146600-0000	O-RING
52/1.	[1]	146420-0000	SHIM D9.5&3.0T1.90
52/1.	[1]	146420-0100	SHIM D9.5&3.0T1.92
52/1.	[1]	146420-0200	SHIM D9.5&3.0T1.94
52/1.	[1]	146420-0300	SHIM D9.5&3.0T1.96
52/1.	[1]	146420-0400	SHIM D9.5&3.0T1.98
52/1.	[1]	146420-0500	SHIM D9.5&3.0T2.00
52/1.	[1]	146420-0600	SHIM D9.5&3.0T2.02
52/1.	[1]	146420-0700	SHIM D9.5&3.0T2.04
52/1.	[1]	146420-0800	SHIM D9.5&3.0T2.06
52/1.	[1]	146420-0900	SHIM D9.5&3.0T2.08
52/1.	[1]	146420-1000	SHIM D9.5&3.0T2.10
52/1.	[1]	146420-1100	SHIM D9.5&3.0T2.12
52/1.	[1]	146420-1200	SHIM D9.5&3.0T2.14
52/1.	[1]	146420-1300	SHIM D9.5&3.0T2.16
52/1.	[1]	146420-1400	SHIM D9.5&3.0T2.18
52/1.	[1]	146420-1500	SHIM D9.5&3.0T2.20
52/1.	[1]	146420-1600	SHIM D9.5&3.0T2.22
52/1.	[1]	146420-1700	SHIM D9.5&3.0T2.24
52/1.	[1]	146420-1800	SHIM D9.5&3.0T2.26
52/1.	[1]	146420-1900	SHIM D9.5&3.0T2.28
52/1.	[1]	146420-2000	SHIM D9.5&3.0T2.30
52/1.	[1]	146420-2100	SHIM D9.5&3.0T2.32
52/1.	[1]	146420-2200	SHIM D9.5&3.0T2.34
52/1.	[1]	146420-2300	SHIM D9.5&3.0T2.36
52/1.	[1]	146420-2400	SHIM D9.5&3.0T2.38
52/1.	[1]	146420-2500	SHIM D9.5&3.0T2.40
52/1.	[1]	146420-2600	SHIM D9.5&3.0T2.42
52/1.	[1]	146420-2700	SHIM D9.5&3.0T2.44
52/1.	[1]	146420-2800	SHIM D9.5&3.0T2.46
52/1.	[1]	146420-2900	SHIM D9.5&3.0T2.48
52/1.	[1]	146420-3000	SHIM D9.5&3.0T2.50
52/1.	[1]	146420-3100	SHIM D9.5&3.0T2.52
52/1.	[1]	146420-3200	SHIM D9.5&3.0T2.54
52/1.	[1]	146420-3300	SHIM D9.5&3.0T2.56
52/1.	[1]	146420-3400	SHIM D9.5&3.0T2.58
52/1.	[1]	146420-3500	SHIM D9.5&3.0T2.60
52/1.	[1]	146420-3600	SHIM D9.5&3.0T2.62
52/1.	[1]	146420-3700	SHIM D9.5&3.0T2.64
52/1.	[1]	146420-3800	SHIM D9.5&3.0T2.66
52/1.	[1]	146420-3900	SHIM D9.5&3.0T2.68
52/1.	[1]	146420-4000	SHIM D9.5&3.0T2.70
52/1.	[1]	146420-4100	SHIM D9.5&3.0T2.72
52/1.	[1]	146420-4200	SHIM D9.5&3.0T2.74
52/1.	[1]	146420-4300	SHIM D9.5&3.0T2.76
52/1.	[1]	146420-4400	SHIM D9.5&3.0T2.78
52/1.	[1]	146420-4500	SHIM D9.5&3.0T2.80
52/1.	[1]	146420-4600	SHIM D9.5&3.0T2.82
52/1.	[1]	146420-4700	SHIM D9.5&3.0T2.84
52/1.	[1]	146420-4800	SHIM D9.5&3.0T2.86
52/1.	[1]	146420-4900	SHIM D9.5&3.0T2.88
52/1.	[1]	146420-5000	SHIM D9.5&3.0T2.90
52/1.	[1]	146420-5100	SHIM D9.5&3.0T1.74
52/1.	[1]	146420-5200	SHIM D9.5&3.0T1.76
52/1.	[1]	146420-5300	SHIM D9.5&3.0T1.78
52/1.	[1]	146420-5400	SHIM D9.5&3.0T1.80
52/1.	[1]	146420-5500	SHIM D9.5&3.0T1.82
52/1.	[1]	146420-5600	SHIM D9.5&3.0T1.84
52/1.	[1]	146420-5700	SHIM D9.5&3.0T1.86
52/1.	[1]	146420-5800	SHIM D9.5&3.0T1.88
54.	[4]	146433-0100	GASKET D12&6.4T1.00
55.	[4]	146430-3220	DELIVERY-VALVE ASSEMBLY
56.	[4]	146432-0000	COMPRESSION SPRING
58.	[4]	146440-0220	FITTING
60.	[3]	139106-0100	FLAT-HEAD SCREW
66.	[1]	146600-0100	O-RING
67.	[1]	146503-5920	GOVERNOR COVER
67/1.	[1]	146805-4920	GOVERNOR COVER
67/13.	[1]	146621-3100	UNION NUT
67/14.	[1]	146621-1700	UNION NUT
67/15.	[1]	146526-6400	BLEEDER SCREW
67/16.	[1]	146526-2800	BLEEDER SCREW
67/78.	[1]	146600-4400	SEAL RING
67/91.	[1]	146929-0400	BRACKET
67/92.	[1]	139006-4500	BLEEDER SCREW
67/200.	[1]	139308-0300	PLAIN WASHER
67/201.	[1]	146545-3400	THREADED PIN L53.00
67/201B.	[1]	146545-3500	THREADED PIN L55.00
67/201C.	[1]	146545-3600	THREADED PIN L57.00
67/202.	[1]	139208-0900	UNION NUT
67/203.	[1]	146600-1200	O-RING
68.	[1]	146513-9920	CONTROL SHAFT
69.	[1]	139310-0200	PLAIN WASHER
72.	[1]	146537-8620	CONTROL LEVER
73.	[1]	014110-6440	LOCKING WASHER
75.	[1]	146621-4200	UNION NUT
82.	[1]	146620-1400	FLAT-HEAD SCREW
83.	[1]	013020-6040	UNION NUT M6P1H5
95.	[1]	146565-6720	FULCRUM LEVER
104.	[2]	146568-0000	SLOTTED SPRING PIN
105.	[2]	026508-1140	GASKET D11.4&8.2T1
106.	[2]	146588-0500	COILED SPRING
107.	[1]	146569-0300	UNION NUT
108.	[1]	146570-0100	GOVERNOR SHAFT
109.	[1]	146600-0400	O-RING
110/1.	[1]	146571-0000	SHIM D20.2&8.3T1.05
110/1.	[1]	146571-0100	SHIM D20.2&8.3T1.25
110/1.	[1]	146571-0200	SHIM D20.2&8.3T1.45
110/1.	[1]	146571-0300	SHIM D20.2&8.3T1.65
110/1.	[1]	146571-0400	SHIM D20.2&8.3T1.85
110/1.	[1]	146571-0500	SHIM D20.2&8.3T1.15
110/1.	[1]	146571-0600	SHIM D20.2&8.3T1.35
110/1.	[1]	146571-0700	SHIM D20.2&8.3T1.55
110/1.	[1]	146571-0800	SHIM D20.2&8.3T1.75
111.	[1]	146602-0600	PLAIN WASHER D20&8.4T1.40
112.	[1]	146572-0020	FLYWEIGHT ASSEMBLY
114.	[1]	146602-0500	PLAIN WASHER D17&6.4T1.60
115.	[1]	146575-2000	SLIDING SLEEVE
116.	[1]	146576-0200	CAP
117/1.	[1]	146577-1800	PLUG L2.10
117/1.	[1]	146577-1900	PLUG L2.30
117/1.	[1]	146577-2000	PLUG L2.50
117/1.	[1]	146577-2100	PLUG L2.70
117/1.	[1]	146577-2200	PLUG L2.90
117/1.	[1]	146577-2300	PLUG L3.10
117/1.	[1]	146577-2400	PLUG L3.30
117/1.	[1]	146577-2500	PLUG L3.50
117/1.	[1]	146577-2600	PLUG L3.70
117/1.	[1]	146577-2700	PLUG L3.90
117/1.	[1]	146577-2800	PLUG L4.10
117/1.	[1]	146577-2900	PLUG L4.30
117/1.	[1]	146577-3000	PLUG L4.50
117/1.	[1]	146577-3100	PLUG L4.70
117/1.	[1]	146577-3200	PLUG L4.90
117/1.	[1]	146577-3300	PLUG L5.10
117/1.	[1]	146577-6700	PLUG L2.2
117/1.	[1]	146577-6800	PLUG L2.4
117/1.	[1]	146577-6900	PLUG L2.6
117/1.	[1]	146577-7000	PLUG L2.8
117/1.	[1]	146577-7100	PLUG L3.0
117/1.	[1]	146577-7200	PLUG L3.2
117/1.	[1]	146577-7300	PLUG L3.4
117/1.	[1]	146577-7400	PLUG L3.6
117/1.	[1]	146577-7500	PLUG L3.8
117/1.	[1]	146577-7600	PLUG L4.0
117/1.	[1]	146577-7700	PLUG L4.2
117/1.	[1]	146577-7800	PLUG L4.4
117/1.	[1]	146577-7900	PLUG L4.6
117/1.	[1]	146577-8000	PLUG L4.8
117/1.	[1]	146577-8100	PLUG L5.0
117/1.	[1]	146877-0000	PLUG L5.2
117/1.	[1]	146877-0100	PLUG L5.3
117/1.	[1]	146877-0200	PLUG L5.4
117/1.	[1]	146877-0300	PLUG L5.5
117/1.	[1]	146877-4700	PLUG
117/1.	[1]	146877-4800	PLUG
117/1.	[1]	146877-4900	PLUG
117/1.	[1]	146877-5000	PLUG
123.	[4]	139106-0200	FLAT-HEAD SCREW
130.	[1]	146421-0020	CAPSULE
130/2.	[1]	026508-1140	GASKET D11.4&8.2T1
130/3.	[1]	146422-0000	BLEEDER SCREW
130/4.	[1]	146600-0500	O-RING
133.	[1]	146600-0600	O-RING
134.	[1]	146600-0700	O-RING
135.	[1]	146110-0220	CONTROL VALVE
135/5.	[1]	146114-0000	SPRING WASHER
136.	[1]	146650-5520	PULLING ELECTROMAGNET
137.	[2]	139514-0200	GASKET
145.	[1]	146621-1000	UNION NUT
147.	[1]	016520-1210	O-RING
162.	[1]	020146-1270	BLEEDER SCREW
200.	[1]	146206-0100	COILED SPRING
217.	[1]	146541-2900	SLOTTED WASHER
218.	[1]	146587-6400	COILED SPRING
219.	[1]	146541-3000	BUSHING
220.	[1]	146587-6500	COILED SPRING
221.	[1]	146928-1420	BRACKET
222.	[2]	139006-4600	BLEEDER SCREW
230.	[1]	146928-5320	BRACKET
231.	[1]	139006-4600	BLEEDER SCREW
236.	[1]	139006-4800	BLEEDER SCREW
237.	[1]	146620-0200	HEX-SOCKET-HEAD CAP SCREW
240.	[1]	146650-0720	PULLING ELECTROMAGNET
240/8.	[1]	146600-1700	O-RING
242.	[1]	146662-1320	WIRE
243.	[1]	146621-1000	UNION NUT
245.	[3]	139512-0200	GASKET D18.5&12.2T1.00
246.	[1]	139812-0500	EYE BOLT
247.	[1]	146665-4820	PIPE
247.	[1]	146665-4820	PIPE
248.	[1]	146614-0200	SPACER BUSHING
275.	[1]	146612-2120	BRACKET
276.	[2]	010010-1640	BLEEDER SCREW M10P1.5L16 4T
280.	[1]	146360-9520	START ADVANCE ASSY
281.	[1]	146600-0800	O-RING
282.	[2]	010206-1240	HEX-SOCKET-HEAD CAP SCREW M6P1L12
287.	[1]	020146-1440	BLEEDER SCREW M6P1L14
309.	[4]	020146-1270	BLEEDER SCREW
309.	[4]	020146-1270	BLEEDER SCREW
309.	[4]	020146-1270	BLEEDER SCREW
310.	[1]	146683-0220	POTENTCIOMETER
311.	[2]	010206-1040	HEX-SOCKET-HEAD CAP SCREW
316.	[1]	146680-4420	DAMPER
318.	[1]	146928-7900	BRACKET
329.	[1]	146541-4900	PLAIN WASHER D20&10T0.5
800S.	[1]	146009-3920	PUMP HOUSING
800S/1/6.	[1]	146601-0900	PACKING RING
804S.	[1]	146232-0720	COMPRESSION SPRING
805S.	[1]	146574-0120	PARTS SET
810S.	[1]	146600-1120	REPAIR SET
835S.	[1]	146598-1000	CAP
836S/1.	[1]	146598-0600	CAP L18
836S/1.	[1]	146598-0700	CAP L21
836S/1.	[1]	146598-0800	CAP L24
836S/1.	[1]	146598-0900	CAP L27
903.	[1]	146672-1120	PULSE GENERATOR
903/2.	[1]	146600-1300	O-RING &13W1.9
906.	[1]	146912-2500	NAMEPLATE

Include in #2:

104740-2281 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 460 611 168 9460611168

ZEXEL 104740-2281 1047402281

Zexel num

Bosch num

Firm num

Name

104740-2281
104740-2282

9 460 611 168

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. 31 30.5 31.5

Difference in delivery mm3/st. 2

Basic *

Injection timing adjustment_02

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 29.4 27.4 31.4

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 28.3 26.3 30.3

Injection timing adjustment_04

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 31 30 32

Injection timing adjustment_05

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 29.8 27.8 31.8

Injection timing adjustment_06

Pump speed r/min 2400 2400 2400

Average injection quantity mm3/st. 29.8 27.8 31.8

Injection timing adjustment_07

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 14.8 12.3 17.3

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 14.8 12.8 16.8

Difference in delivery mm3/st. 4.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2900 2900 2900

Average injection quantity mm3/st. 6

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 9.6 8.6 10.6

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 9.6 8.6 10.6

Governor adjustment_03

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 3

Boost compensator adjustment

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 13.5 7.5 19.5

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 55 75

Basic *

Speed control lever angle

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1000 1000 1000

Overflow quantity with S/T ON cm3/min 441 312 570

Stop lever angle

Pump speed r/min 1000 1000 1000

Pressure kPa 411.5 382 441

Pressure kgf/cm2 4.2 3.9 4.5

Basic *

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Pressure with S/T ON kPa 411.5 382 441

Pressure with S/T ON kgf/cm2 4.2 3.9 4.5

Stop lever angle_03

Pump speed r/min 1400 1400 1400

Pressure with S/T ON kPa 510 481 539

Pressure with S/T ON kgf/cm2 5.2 4.9 5.5

Stop lever angle_04

Pump speed r/min 1800 1800 1800

Pressure with S/T ON kPa 598.5 569 628

Pressure with S/T ON kgf/cm2 6.1 5.8 6.4

Stop lever angle_05

Pump speed r/min 2400 2400 2400

Pressure with S/T ON kPa 735.5 706 765

Pressure with S/T ON kgf/cm2 7.5 7.2 7.8

0000001101

Pump speed r/min 1000 1000 1000

Timer stroke with S/T ON mm 4.4 4.2 4.6

Timer stroke with S/T OFF mm 3.2 2.8 3.6

Basic *

_02

Pump speed r/min 600 600 600

Timer stroke with S/T ON mm 1.9 1.3 2.5

_03

Pump speed r/min 1000 1000 1000

Timer stroke with S/T ON mm 4.4 4.1 4.7

Timer stroke with S/T OFF mm 3.2 2.7 3.7

Remarks
ON

_04

Pump speed r/min 1400 1400 1400

Timer stroke with S/T ON mm 6.4 5.8 7

_05

Pump speed r/min 1800 1800 1800

Timer stroke with S/T ON mm 8.5 7.9 9.1

_06

Pump speed r/min 2400 2400 2400

Timer stroke with S/T ON mm 10.6 10.1 11.1

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 0.9 0.8 1

Control lever angle alpha deg. 25 23 27

Control lever angle beta deg. 44 39 49

Control lever angle gamma deg. 11 10.5 11.5

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. At N = N1 and control lever position a (corresponding to shim thickness L), measure the injection quantity, calculate the voltage from the graph, and then adjust the potentiometer. A:Performance standards C:Position of the control lever N:Pump speed Vo:Output voltage E:Conversion formula (J) G:Idle H:Full speed K:Applied voltage X:Injection quantity (mm3/st) Y:Voltage (V) M:Connecting diagram for the potentiometer O:Output P:Output when (2) and (3) connected.
----------
N1=700r/min a=11deg L=7.0mm
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V1=Measure V2=Measure J:7.5<=X<=11.5cm3/1000st V+-0.03=0.01346X+2.634 11.5<=X<=19.5cm3/1000st V+-0.03=0.0977X+3.059 K=10V

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Setting the intermediate lever position (Refer to Fig. 1(O), 2(P).) (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. 2. Adjustment of the W-CSD lever (Refer to Fig. 1(O), 2(P).) (1)After completing (1) above, remove the block gauge L3 and the shim with the thickness L4. (2)Insert a block gauge L5 determined from the graph (L-t) 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) Y:Control lever L dimension (mm; control lever position) J:L-theta graph t (deg C) <= 10: L = 3.9 10 <= t (deg C) <= 30: L =-0.09t + 4.8 30 <= t (deg C) <= 54.3: L = -0.086t + 4.68
----------
L1=L=3.0+-0.05mm L2=5.3+-0.05mm L3=3.0mm L4=5.3mm L5=L+-0.05mm a=30degC
----------
L=3.0+-0.05mm L4=5.3mm

0000002001 DASHPOT ADJUSTMENT

Adjustment of the dash pot 1. Insert a block gauge L (thickness gauge) between the idle set screw (C) and the control lever (D). 2. In the above condition, adjust so that the dashpot adjusting screw (A) contacts the pushrod. Then, fix using the locknut (B) (Tightening torque T3). 3. Confirm that the control lever returns to the idling position without the adjusting screw or dashpot sticking or coming loose. (E) 3 locations
----------
T3=4.9~6.9(N-m)(0.5~0.7(kgf-m)) L=6.0+-0.05(mm)
----------
T1=14.7~19.6(N-m)(1.5~2.0(kgf-m)) T2=5.9~8.8(N-m)(0.6~0.9(kgf-m)) SW1=22(mm) SW2=10(mm) L=6.0+-0.05(mm)

0000002101 CONTROL LEVER ANGLE

Control lever angle measurement 1. Measure the dimension L from the lever tip to the flange face (A). 2. Measure the lever angle from the pin hole R (plate). (B): lever angle measuring hole Alpha = a beta: b
----------
R=61.5mm L=14.1~19.4mm
----------
R=61.5mm a=23~27deg b=39~49deg L=14.1~19.4mm

Information:

Battery
Never disconnect any charging unit circuit or battery circuit cable from battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result.
The battery circuit is an electrical load on the charging unit. The load is variable because of the condition of the charge in the battery. Damage to the charging unit will result if the connections (either positive or negative) between the battery and charging unit are broken while the charging unit is in operation. This is because the battery load is lost and there is an increase in charging voltage. High voltage will damage, not only the charging unit, but also the regulator and other electrical components.Use the 4C4911 Battery Load Tester, the 8T900 Clamp-On Ammeter and the 6V7070 Multimeter to load test a battery that does not hold a charge when in use. See Special Instruction, Form No. SEHS8268 for the correct procedure and specifications to use.Charging System
The condition of charge in the battery at each regular inspection will show if the charging system operates correctly. An adjustment is necessary when the battery is constantly in a low condition of charge or a large amount of water is needed (more than one ounce of water per cell per week or per every 100 service hours).When it is possible, make a test of the charging unit and voltage regulator on the engine, and use wiring and components that are a permanent part of the system. Off-engine (bench) testing will give a test of the charging unit and voltage regulator operation. This testing will give an indication of needed repair. After repairs are made, again make a test to give proof that the units are repaired to their original condition of operation.Before the start of on-engine testing, the charging system and battery must be checked as shown in the Steps that follow:1. Battery must be at least 75% (1.225 Sp. Gr.) fully charged and held tightly in place. The battery holder must not put too much stress on the battery.2. Cables between the battery, starting motor and engine ground must be the correct size. Wires and cables must be free of corrosion and have cable support clamps to prevent stress on battery connections (terminals).3. Leads, junctions, switches and panel instruments that have direct relation to the charging circuit must give correct circuit control.4. Inspect the drive components for the charging unit to be sure they are free of grease and oil and have the ability to operate the charging unit.9L5938 Alternator; Pulley Nut Tightening
Tighten nut that holds the pulley to a torque of 100 7 N m (75 5 lb ft) with the tools shown.
Tools To Tighten Alternator Pulley Nut
(1) 8T9293 Torque Wrench. (2) 8S1588 Adapter (1/2 inch female to 3/8 inch male). (3) 2P8267 Socket Assembly. (4) 8H8517 Combination Wrench (1 1/8 inch). (5) 8T5314 Socket.Starting System
Use