104741-3790 ZEXEL 9 460 613 497 BOSCH INJECTION-PUMP ASSEMBLY 9460613497 1047413790

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 613 497 9460613497

ZEXEL 104741-3790 1047413790

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Cross reference number

BOSCH 9 460 613 497 9460613497

ZEXEL 104741-3790 1047413790

Zexel num

Bosch num

Firm num

Name

104741-3790
104741-3791

9 460 613 497

INJECTION-PUMP ASSEMBLY
* K 11CJ VE4 VE

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 750 750 750

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 48.5 48 49

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 750 750 750

Boost pressure kPa 46.7 45.4 48

Boost pressure kgf/cm2 0.48 0.466 0.494

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 65.4 64.9 65.9

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 81.1 80.6 81.6

Difference in delivery mm3/st. 6.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 48.5 47.5 49.5

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 750 750 750

Boost pressure kPa 46.7 45.4 48

Boost pressure kgf/cm2 0.48 0.466 0.494

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 65.4 64.4 66.4

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 81.1 80.1 82.1

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 2000 2000 2000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 68.6 64.6 72.6

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2475 2475 2475

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 26.4 23.4 29.4

Difference in delivery mm3/st. 8

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 3000 3000 3000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 8

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2475 2475 2475

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Average injection quantity mm3/st. 26.4 21.4 31.4

Difference in delivery mm3/st. 8.5

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 18.9 16.9 20.9

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 18.9 16.4 21.4

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5

Oil temperature degC 50 48 52

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 91.7 71.7 111.7

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 91.7 71.7 111.7

Oil temperature degC 48 46 50

Remarks
IDLE

Speed control lever angle

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

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 1250 1250 1250

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Overflow quantity with S/T ON cm3/min 670 540 800

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Pressure with S/T ON kPa 647 608 686

Pressure with S/T ON kgf/cm2 6.6 6.2 7

Pressure with S/T OFF kPa 500 480 520

Pressure with S/T OFF kgf/cm2 5.1 4.9 5.3

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

0000001101

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Timer stroke with S/T ON mm 6.8 6.3 7.3

Timer stroke with S/T OFF mm 3.4 3.2 3.6

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Timer stroke with S/T ON mm 3.9 3.2 4.6

Timer stroke with S/T OFF mm 1

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Timer stroke with S/T OFF mm 2 1.3 2.7

Oil temperature degC 50 48 52

_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Timer stroke with S/T ON mm 6.8 6.1 7.5

Timer stroke with S/T OFF mm 3.4 3 3.8

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Timer stroke with S/T OFF mm 6.3 5.6 7

Oil temperature degC 50 48 52

_06

Pump speed r/min 2300 2300 2300

Boost pressure kPa 86.6 85.3 87.9

Boost pressure kgf/cm2 0.88 0.866 0.894

Boost pressure mmHg 650 640 660

Timer stroke with S/T ON mm 8.6 8.1 9

Timer stroke with S/T OFF mm 8 7.3 8.7

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 5.8 5.7 5.9

MS dimension mm 0.6 0.5 0.7

BCS stroke mm 6.8 6.6 7

Control lever angle alpha deg. 59 55 63

Control lever angle beta deg. 40 35 45

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 using the following graph. (2)(1) Adjust with the screw (A) so that the timer advance angle determined in the item (1) is obtained. X:Temperature t (deg C) Y:Timer stroke TA (mm) (B): Timer stroke TA (mm):
----------

----------
(B)=TAmm (C)=TA=-0.04t+1.2{0<=t<=30(degC)} X=tdegC Y=TAmm

0000001901 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Adjusting method (service voltage Vi, dummy bolt): 1. Hold the dummy bolt against the control lever when N = N1 r/min, Q = Q1 mm3/st. Fix using the lock nut. 2. When adjusting the potentiometer, position the control lever against the dummy bolt and adjust the potentiometer so that the output voltage is V1 (V). 3. Remove the dummy bolt after the completion of adjustment. Confirm that the potentiometer output voltage is within the standards mentioned when the control lever is idling and in full-speed position. Vi:Applied voltage C:Position of the control lever N:Pump speed (r/min) V:Output voltage (V) Q:Injection quantity (mm3/st) A:Adjusting point B:Checking point C1:Idling C2:Full speed P1:Boost pressure P2:Boost pressure
----------
N1=750r/min V1=4.16+-0.03V Q1=34.7+-1.0cm3/1,000st
----------
N1=750(r/min) V1=4.16+-0.03(V) V2=(2.16+-0.52)(V) V3=(9.02+-0.72)(V) Q1=34.7+-1.0(cm3/1,000st) Vi=10V

0000002001

2. Adjustment of the W-FICD (1)Insert a block gauge L1 determined from the graph below between the control lever (D) and the idle set screw (C). (2)Tighten the nut (F) at the position where the W-FICD lever (E) the control lever (D) contact. T2T2 (3)After adjusting the W-FICD lever (E), confirm that the timer stroke is the value adjusted in item 1. Then, remove the shim. Y = control lever position X = temperature G = control lever position: (mm)
----------
L1=L+-0.3 mm T2=6~9 N-m{0.6~0.9 kgf-m}
----------
L1=L+-0.3 mm SW2=SW10 T2=6~9 N-m{0.6~0.9 kgf-m} SW1=SW8 T1=3.4~4.9 N-m{0.35~0.5 kgf-m}

Information:

* Check that there is continuity between each stator lead.* If there is no continuity, the lead has broken.(2) Continuity between each lead wires and the core * Check that there is no continuity between lead wires and the core.* If there is continuity, the lead wire has short-circuited. Inspection: Brush* If the length of the brush has reached wear limit, replace the brush. Inspection: Rectifier* Check the function of diodes within rectifier properly. If any fault is found, replace the rectifier. If resistance is infinite in both cases, the diode is open.If resistance is close to 0 ohms in both cases, the diode is shorted.A, B, C: Lead connecting area of stator coilD, F: Heat sink areaE: Regulator connecting area* Inspection should be conducted twice, changed over the positive probe and the negative probe of the tester.* When inspecting using a tester, the current flowing through the rectifier is smaller than usual. Therefore, an incorrect resistance value may be indicated on the tester. Additionally, incorrect indications become larger as the range of the tester gets smaller. Set the tester to the largest possible scale. Assembly Procedure Assembly: Regulator and brush holder* To install the regulator and brush holder, follow the disassembly sequence in reverse. (See " Disassembly: Regulator and brush holder".) Assembly: Brush * Install brush on regulator and brush holder in the direction as illustrated.* After installation, solder the lead wire of brush on the regulator and brush holder. Thereafter, fit the cover as it was. Assembly: Stator* To install the stator, follow the disassembly sequence in reverse. (See " Disassembly: Stator".) Assembly: Rotor and rear bracket * If brush protrudes from regulator and brush holder, rotor cannot be installed onto the rear bracket. In this case, do the following:* Push brush into regulator and brush holder.* Insert pin into rear bracket from the rear to hold brush.* After assembly, remove pin gently.#950 Inspection Of Alternator
Performance Test* The general inspection is only a simplified check. use a test bench for accurate checking.* Connect the meters to the alternator as shown.
* To prevent possible injury, be sure to disconnect the negative terminal of