104740-9692 ZEXEL 9 460 610 645 BOSCH INJECTION-PUMP ASSEMBLY 9460610645 1047409692

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 610 645 9460610645

ZEXEL 104740-9692 1047409692

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Cross reference number

BOSCH 9 460 610 645 9460610645

ZEXEL 104740-9692 1047409692

Zexel num

Bosch num

Firm num

Name

104740-9692

9 460 610 645

INJECTION-PUMP ASSEMBLY
K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105000-2010

Bosch type code NP-DN12SD12TT

Nozzle holder 105780-2080

Opening pressure MPa 14.7 14.7 15.19

Opening pressure kgf/cm2 150 150 155

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840

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 1100 1100 1100

Average injection quantity mm3/st. 52.2 51.7 52.7

Difference in delivery mm3/st. 3

Basic *

Injection timing adjustment_02

Pump speed r/min 2550 2550 2550

Average injection quantity mm3/st. 10.1 5.6 14.6

Injection timing adjustment_03

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 33 30.5 35.5

Injection timing adjustment_04

Pump speed r/min 2150 2150 2150

Average injection quantity mm3/st. 42.9 40.8 45

Injection timing adjustment_05

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 52.2 51.2 53.2

Injection timing adjustment_06

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 52.8 50.8 54.8

Injection quantity adjustment

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 33 31 35

Basic *

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 5

Governor adjustment

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 7.3 5.3 9.3

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 7.3 5.3 9.3

Governor adjustment_03

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 3

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 62.5 45 80

Basic *

Speed control lever angle

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1100 1100 1100

Overflow quantity cm3/min 390 258 522

Stop lever angle

Pump speed r/min 750 750 750

Pressure kPa 362.5 343 382

Pressure kgf/cm2 3.7 3.5 3.9

Basic *

Stop lever angle_02

Pump speed r/min 750 750 750

Pressure kPa 362.5 343 382

Pressure kgf/cm2 3.7 3.5 3.9

Stop lever angle_03

Pump speed r/min 1100 1100 1100

Pressure kPa 431.5 402 461

Pressure kgf/cm2 4.4 4.1 4.7

Stop lever angle_04

Pump speed r/min 1700 1700 1700

Pressure kPa 578.5 549 608

Pressure kgf/cm2 5.9 5.6 6.2

Stop lever angle_05

Pump speed r/min 2150 2150 2150

Pressure kPa 676.5 647 706

Pressure kgf/cm2 6.9 6.6 7.2

0000001101

Pump speed r/min 750 750 750

Timer stroke mm 1.2 1 1.4

Basic *

_02

Pump speed r/min 750 750 750

Timer stroke mm 1.2 0.9 1.5

_03

Pump speed r/min 1100 1100 1100

Timer stroke mm 2.5 1.9 3.1

_04

Pump speed r/min 1700 1700 1700

Timer stroke mm 4.9 4.2 5.6

_05

Pump speed r/min 2550 2550 2550

Timer stroke mm 7.3 6.8 7.8

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 5.8 5.7 5.9

MS dimension mm 0.9 0.8 1

Control lever angle alpha deg. 55.5 51.5 59.5

Control lever angle beta deg. 36 31 41

Test data Ex:

0000001801 CONTROL LEVER ANGLE

Control lever angle measurement 1. Measure dimension Ya between the end of the lever and the flange face B. 2. Measure the lever angle from the R (plate) pin hole. (A) Lever angle measurement position
----------
Ya=8.4~12.2mm R=53mm
----------
Ya=8.4~12.2mm R=53mm Alpha=51.5~59.5deg Beta=31~41deg

0000001901 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Measure the injection quantity with the control lever a from the idle position (equal to shim thickness L1) at pump speed N5. Install the potentiometer so that injection quantity and output voltage correspond as shown in the graph. Confirm at least V5 at full lever position. Conversion formula V+-0.03 = 0.0672X + 1.6031 A = shim thickness B = changeover point C = control lever angle D = lever position (from idle) E = adjusting point Vi = applied voltage V = potentiometer voltage X = injection quantity Q Y = voltage (V) B1 = idle switch ON to OFF B2 = full switch OFF to ON F = potentiometer wiring diagram G = output between connections (2) and (3) H = switch OFF to ON at connections 4 and 6. I = switch ON to OFF at connecting harnesses 4 and 5 J = output N = pump speed Q = injection quantity
----------
N5=750r/min a=8.0deg L1=5.3mm V5=6V
----------
N1=500r/min N2=-r/min N3=-r/min N4=-r/min V1=2.8V V2=-V V3=-V V4=-V Q1=17.8+-1.0cm3/1,000st Q2=-cm3/1,000st Q3=-cm3/1,000st Q4=- cm3/1,000st C1=(8.0)deg C2=-deg C3=-deg C4=-deg A1=(5.3)mm A2=-mm A3=-mm A4=-mm Vi=10 V D1=5.7+-3.5deg D2=20.2+-3.5deg

Information:

Table 9
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $01 CCM is the sending module
3 $25 IID 25
4 $07 Number of bytes
5 $58 GSC number 1
6, 7 $00 $82 PID $0082 GSC Fault Log Codes, Status, And Number of occurrences
8, 9 $00 $BE CID 190 (engine speed sensor fault)
10 $C3 Count included, inactive fault, logged fault, standard FMI (3)
11 $04 Occurrence count of 4
12 $24 Checksum
IID 00 is used to request additional information on a fault 500000070058008300BEC34DIID 00 - Special parameter Command
Table 10
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $01 CCM is the sending module
3 $00 IID 00
4 $07 Number of bytes
5 $00 Reply in ASCII format
6 $58 GSC number 1
7, 8 $00 $83 PID $0083 GSC Fault Log Request For Additional Data
9, 10, 11 $00 $BE $C3 More information requested on CID 190 FMI 3
12 $4D Checksum
IID 25 will contain the reply as PID $0084 5001250B58008400BEC303000C001102IID 25 - Single Parameter Read Response
Table 11
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $01 CCM is the sending module
3 $25 IID 25
4 $0B Number of bytes
5 $58 GSC number 1
6, 7 $00 $84 PID $0084 GSC Fault Log Response For Additional Data
8, 9 $00 $BE CID 190
10 $C3 More information on FMI 3
11 $03 Three occurrences of this fault
12, 13 $00 $0C First occurrence at 12 hours
14, 15 $00 $11 Last occurrence at 17 hours
16 $02 Checksum Monitoring Generator Phase
The following example shows how to select which generator phase the GSC monitors.
Use IID 34 to write the parameters of PID $F0B0: 500034050048F0B0007FIID 34 - Single Parameter Write Request
Table 12
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $00 User's PC is the sending module
3 $34 IID 34
4 $05 Number of bytes
5 $00 Reply in ASCII format
6 $58 GSC number 1
7, 8 $F0 $B0 PID $F0B0 Generator Phase Select
9 $00 Phase A-B Voltage, Phase A Current
10 $7F Checksum
IID 35 is the response from the CCM: 5001350458F0B0007EIID 35 - Single Parameter Write Response
Table