104741-5200 ZEXEL 9 460 614 442 BOSCH INJECTION-PUMP ASSEMBLY 9460614442 1047415200 8970283220

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 442 9460614442

ZEXEL 104741-5200 1047415200

ISUZU 8970283220 8970283220

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Cross reference number

BOSCH 9 460 614 442 9460614442

ZEXEL 104741-5200 1047415200

ISUZU 8970283220 8970283220

Zexel num

Bosch num

Firm num

Name

104741-5200

9 460 614 442

8970283220 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1CGT * 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)
Left L

(Solenoid timer adjustment condition)
With S/T O-ring; S/T OFF. OFF

Timer measuring device installation position
Low pressure side LOW PRESSURE SIDE

Injection timing adjustment

Pump speed r/min 1250 1250 1250

Boost pressure kPa 46.7 45.4 48

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 49.1 48.6 50.6

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 60.9 60.4 61.4

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 600 600 600

Boost pressure kPa 13.3 12 14.6

Boost pressure mmHg 100 90 110

Average injection quantity mm3/st. 35.8 31.8 39.8

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 24 22.7 25.3

Boost pressure mmHg 180 170 190

Average injection quantity mm3/st. 38.2 38.2 38.2

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 900 900 900

Boost pressure kPa 46.7 45.4 48

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 48.2 48.2 48.2

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Boost pressure kPa 46.7 45.4 48

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 49.1 48.1 50.1

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1250 1250 1250

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 60.9 59.9 61.9

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 1800 1800 1800

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 58.3 54.8 61.8

Difference in delivery mm3/st. 5.5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 16.5 13.5 19.5

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2600 2600 2600

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2300 2300 2300

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 16.5 13.5 19.5

Difference in delivery mm3/st. 4.5

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 7 5 9

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 7 5 9

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 80 60 100

Basic *

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 mmHg 0 0 0

Average injection quantity mm3/st. 80 60 100

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 375 375 375

Boost pressure kPa 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 1600 1600 1600

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Oil temperature degC 50 48 52

Remarks
MEASURE

Stop lever angle

Pump speed r/min 1600 1600 1600

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Pressure with S/T OFF kPa 490 470 510

Pressure with S/T OFF kgf/cm2 5 4.8 5.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1050 1050 1050

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Pressure with S/T OFF kPa 314 285 343

Pressure with S/T OFF kgf/cm2 3.2 2.9 3.5

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1600 1600 1600

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Pressure with S/T OFF kPa 490 470 510

Pressure with S/T OFF kgf/cm2 5 4.8 5.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1800 1800 1800

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Pressure with S/T OFF kPa 539 510 568

Pressure with S/T OFF kgf/cm2 5.5 5.2 5.8

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1600 1600 1600

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Timer stroke with S/T OFF mm 5 4.8 5.2

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 520 520 520

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Timer stroke with S/T ON mm 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1050 1050 1050

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Timer stroke with S/T OFF mm 0.5 0.1 0.9

Oil temperature degC 50 48 52

_04

Pump speed r/min 1600 1600 1600

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Timer stroke with S/T OFF mm 5 4.8 5.2

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 1800 1800 1800

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Timer stroke with S/T OFF mm 6.2 5.9 6.6

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 2.8 2.7 2.9

KF dimension mm 5.5 5.4 5.6

MS dimension mm 0.9 0.8 1

BCS stroke mm 4.8 4.6 5

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 37 32 42

Information:

Disassembly and Reassembly of General Parts
Oil seals
When installing oil seals, observe the following.Installation of Oil Seals to Housings
(a) Check the seal lip for scratches and damage, and be sure to position the lip correctly.(b) Apply a small amount of grease to the periphery (housing contact surface) of the oil seal before installation.(c) Use an oil seal driver that guides the seal lip and presses the seal periphery, as shown in the diagram on the right. Striking the oil seal directly with a hammer causes seal damage and results in oil leaks.
Oil seal driverInstallation of Oil Seals to Shafts
(a) Apply grease to the oil seal lip.(b) Use an oil seal guide similar to the one shown in the diagram when installing an oil seal over the stepped portion, splines, threads or key grooves.
Oil seal guideO-rings
Use an O-ring guide similar to the one shown in the diagram when installing an O-ring over the stepped portion, splines, threads or key grooves. Be sure to apply a small amount of grease to the O-ring before installation.
O-ring guideBearings
Bearing Driver(1) When installing a bearing, be sure to push the inner or outer race that fits into the installation position. (When the inner race fits into the installation position, push the inner race into position. When the outer race fits into the installation position, push the outer race into position.) Be sure to use a bearing driver similar to the one shown in the diagram.(2) Use of a press minimizes the impact on the bearing and ensures proper installation.
Using press for bearing installationLock Plates
Be sure to bend lock plates. The diagram on the right shows the methods of bending representative lock plates.
Bending lock plateSplit Pins and Spring Pins
Generally, new split pins should be installed whenever split pins are removed. Be sure to bend split pins. Be sure to check spring pins for secure installation.Engine Inspection Record Sheet
1. Measurement of Cylinder Bore Diameter2. Measurement of Clearance between Valve Stem and Valve Guide, and Valve Stem Diameter3. Measurement of Valve Sinkage, Seat Width and Valve Margin4. Measurement of Distortion of Cylinder Head Bottom Surfaces5. Measurement of Oil Clearance of Connecting Rod Bearing6. Measurement of Rocker Arm Inside Diameter and Shaft Diameter7. Measurement of Piston Pin Bore Diameter and Piston Pin Diameter8. Measurement of Valve Clearance9. Measurement of Injection Pressure of Fuel Injection Nozzle10. Measurement of Clearance between Camshaft Journal Bore Diameter and Camshaft Bushing11. Measurement of Crankshaft End PlayEngine Inspection Record Sheet No. 1 Engine Inspection Record Sheet No. 2 Engine Inspection Record Sheet No. 3 Engine Inspection Record Sheet No. 4 Engine Inspection Record Sheet No. 5 Engine Inspection Record Sheet No. 6 Engine Inspection Record Sheet No. 7 Engine Inspection Record Sheet No. 8 Engine Inspection Record Sheet No. 9 Engine Inspection Record Sheet No. 10 Engine Inspection Record Sheet No. 11