104740-6130 ZEXEL 9 460 620 022 BOSCH INJECTION-PUMP ASSEMBLY 9460620022 1047406130 8971433270

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 620 022 9460620022

ZEXEL 104740-6130 1047406130

ISUZU 8971433270 8971433270

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Cross reference number

BOSCH 9 460 620 022 9460620022

ZEXEL 104740-6130 1047406130

ISUZU 8971433270 8971433270

Zexel num

Bosch num

Firm num

Name

104740-6130

9 460 620 022

8971433270 ISUZU

INJECTION-PUMP ASSEMBLY
4EE1 * 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)
Right R

Injection timing adjustment

Pump speed r/min 1325 1325 1325

Average injection quantity mm3/st. 34.9 34.4 35.4

Difference in delivery mm3/st. 3.5

Basic *

Injection timing adjustment_02

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 37.7 33.7 41.7

Injection timing adjustment_03

Pump speed r/min 510 510 510

Average injection quantity mm3/st. 34.3 31.5 37.1

Injection timing adjustment_04

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 33.3 30.5 36.1

Injection timing adjustment_05

Pump speed r/min 1325 1325 1325

Average injection quantity mm3/st. 34.9 33.9 35.9

Difference in delivery mm3/st. 3.5

Basic *

Injection timing adjustment_06

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 35.6 33.6 37.6

Injection timing adjustment_07

Pump speed r/min 2200 2200 2200

Average injection quantity mm3/st. 35.3 33.3 37.3

Injection quantity adjustment

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 17.1 14.1 20.1

Difference in delivery mm3/st. 5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2400 2400 2400

Average injection quantity mm3/st. 34.3 28.8 37.8

Injection quantity adjustment_03

Pump speed r/min 2600 2600 2600

Average injection quantity mm3/st. 17.1 13.6 20.6

Difference in delivery mm3/st. 5

Basic *

Injection quantity adjustment_04

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 5

Governor adjustment

Pump speed r/min 435 435 435

Average injection quantity mm3/st. 12.5 10.5 14.5

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 435 435 435

Average injection quantity mm3/st. 12.5 10.5 14.5

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_03

Pump speed r/min 620 620 620

Average injection quantity mm3/st. 5

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 51.5 41.5 61.5

Basic *

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 51.5 41.5 61.5

Remarks
IDLE

Speed control lever angle

Pump speed r/min 435 435 435

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1250 1250 1250

Overflow quantity cm3/min 600 470 730

Stop lever angle

Pump speed r/min 1250 1250 1250

Pressure kPa 392 372 412

Pressure kgf/cm2 4 3.8 4.2

Basic *

Stop lever angle_02

Pump speed r/min 850 850 850

Pressure kPa 284 255 313

Pressure kgf/cm2 2.9 2.6 3.2

Basic *

Stop lever angle_03

Pump speed r/min 1250 1250 1250

Pressure kPa 392 372 412

Pressure kgf/cm2 4 3.8 4.2

Stop lever angle_04

Pump speed r/min 2100 2100 2100

Pressure kPa 618 579 657

Pressure kgf/cm2 6.3 5.9 6.7

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke mm 2.6 2.4 2.8

Basic *

_02

Pump speed r/min 850 850 850

Timer stroke mm 0.5 0.1 1.5

_03

Pump speed r/min 1250 1250 1250

Timer stroke mm 2.6 2.3 2.9

Basic *

_04

Pump speed r/min 1750 1750 1750

Timer stroke mm 5 4.4 5.6

_05

Pump speed r/min 2100 2100 2100

Timer stroke mm 6.2 5.8 6.6

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 22.7 21.7 23.7

Timer stroke TA mm 2.3 2.3 2.3

Timer stroke variation dT mm 0.3 0.1 0.5

Basic *

_02

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 22.7 21.2 24.2

Timer stroke TA mm 2.3 2.3 2.3

Timer stroke variation dT mm 0.3 0 0.6

Basic *

_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 10.8 9.3 12.3

Timer stroke TA mm 1.5 1.5 1.5

Timer stroke variation dT mm 1.1 0.6 1.6

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.3 5.2 5.4

MS dimension mm 0.8 0.7 0.9

Pre-stroke mm 0.1 0.08 0.12

Control lever angle alpha deg. 20 16 24

Control lever angle beta deg. 44 40 48

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Adjustment method (supply voltage Vi, dummy bolt method) 1. Hold the dummy bolt (A) against the control lever at position N = N1 and Q = Q1 and fix using the lock nut. 2. When adjusting the potentiometer, position the control lever against the dummy bolt (A) and adjust so that the output voltage is V1. 3. After adjustment, remove the dummy bolt and confirm that the potentiometer output voltage at the control lever's idling and full positions is as specified in the table. (A) Dummy bolt N:Pump speed V:Output voltage Q:Injection quantity C/L: control lever position I:Idling lever position F:Full speed lever position B:Adjusting point C:Checking point
----------
N1=1000r/min V1=4.95+-0.03V Q1=17.3~19.3mm3/st
----------
N1=1000r/min Q1=17.3~19.3mm3/st V1=4.95+-0.03V V2=1.80+-0.45V V3=9.13+-0.65V

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the timer stroke Adjust using screw (A) so that the timer stroke is the value determined using the graph (M). [(K), (M)] 2. Adjustment of the position of the intermediate lever. Insert the shim (L1) between the control lever (I) and the idle set screw (G). Align the intermediate lever (F) with the aligning mark (J) and fix the intermediate lever screw (E) so that it contacts the control lever. [(K), (L)] 3. Adjustment of the FICD Insert the shim (L2) between the control lever (I) and the idle set screw (G). Fix with the adjusting screw to the position where the CSD lever (C) actuates the intermediate lever through the rod (D). (K), (L), (M) (O) Timer stroke adjustment (mm) - (1):TA = -0.0235t+1.37 (-20 deg <= t <=60 deg C) (P) Lever position (deg) 2:theta 1 = -0.0625t+5.65 (-20 deg C <= t <= 20 deg C) Theta 2 = -0.1108t + 6.62 (20 deg C =< t =< 60 deg C) (Q) lever position (mm) 3: L1 = -0.02075t+1.878 (-20 deg C <= t <= 20 deg C) L2 = -0.03900t + 2.277 (20 deg C =< t =< 60 deg C) The (Q) indicates the clearance between the control lever and the idle set screw. (R) Cooling water temperature (deg C) (S) Cooling water temperature: increase direction N:Pump speed X:Temperature t (deg C) Y1:Timer stroke TA (mm) Y2:Control lever position at theta L (deg, mm) (T) Timer piston stroke (mm) (U) Lever position (deg) (W) Lever position (mm)
----------
L1=2.1+-0.05mm L2=L1+-0.05mm
----------
N1=500r/min a=20degC b=-20degC c=4.4+-1deg d=6.9+-3deg T1=0.9+-0.4mm T2=1.8+-0.5mm W1=1.5+-0.3mm W2=2.3+-1mm

Information:

Failure to follow these oil recommendations can cause shortened engine life due to deposits and or excessive wear.
Total Base Number (TBN) and Fuel Sulfur Levels For Caterpillar Prechamber Combustion (PC) Diesel Engines
New engine oil must have a TBN of 20 times (for Precombustion Chamber engines) and ten times (for direct injection engines) the percent fuel sulfur as measured by ASTM D2896 method. Refer to the following chart.
Y=oil TBN shown by ASTM D2896. X=percent of fuel sulfur by weight. New oil TBN (1). Change oil when the used oil TBN limit (2) is reached.Caterpillar's 20 times rule for TBN (Reference: Oil and Your Engine, SEBD0640) versus fuel sulfur was a general requirement developed in the early 1980's for Cat prechamber combustion (PC) system engines. Caterpillar still maintains 20 times TBN value for PC engines when using API CE or CF-4 oil (related to fuel sulfur above 0.5 percent). Engines built prior to 1990 can continue to use single grade viscosity oil or commercial oils, provided the engine operates to user satisfaction.Fuel sulfur neutralization of new oil formulations in direct injection (DI) system engines are more effective. Field results indicate that direct injection combustion (DI) systems and the oils now recommended for those engines will operate at an oil TBN equal to ten times the fuel sulfur.Total Base Number (TBN) and Fuel Sulfur Levels For Caterpillar Direct Injection (DI) Diesel Engines
The TBN for a new oil is dependent on the sulfur level of the fuel used. For direct injection engines running distillate diesel fuel, the minimum new oil TBN (by ASTM D 2896) must be 10 times the fuel sulfur level, and the minimum TBN is 5 regardless of sulfur level, see the chart below.TBN vs Fuel Sulfur for Caterpillar DI Diesel Engines
Y=oil TBN shown by ASTM D2896. X=percent of fuel sulfur by weight. New oil TBN (1). Change oil when the used oil TBN limit (2) is reached.In areas where the fuel sulfur exceeds 1.5 percent, choose an oil with the highest TBN that is within the API CF-4 or CG-4 categories, and shorten the oil change period based on oil analysis. The oil analysis should evaluate oil condition and wear metals. High TBN oils that are not within the API CF-4 or CG-4 categories can produce excessive piston deposits leading to a loss of oil control and bore polishing.
Operation at fuel sulfur levels over 1.5 percent may require shortened oil change periods to maintain adequate wear protection.
Lubricant Viscosity Recommendations
The proper SAE viscosity grade oil is determined by the minimum outside temperature at cold engine start up, and the maximum outside temperature during engine operation. Use the minimum temperature column on the chart to determine the oil viscosity required for starting a "cold soaked" engine. Use the maximum temperature column on the chart to select the viscosity for operation at the highest temperature anticipated. In general, use the highest viscosity oil available that still meets the start up temperature requirements. Synthetic Base Stock Oils
Synthetic base stock oils are acceptable