104741-5480 ZEXEL 9 460 610 472 BOSCH INJECTION-PUMP ASSEMBLY 9460610472 1047415480 8970430231

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 610 472 9460610472

ZEXEL 104741-5480 1047415480

ISUZU 8970430231 8970430231

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Cross reference number

BOSCH 9 460 610 472 9460610472

ZEXEL 104741-5480 1047415480

ISUZU 8970430231 8970430231

Zexel num

Bosch num

Firm num

Name

104741-5480
104741-5481

9 460 610 472

8970430231 ISUZU

INJECTION-PUMP ASSEMBLY
4JG2-TC * 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 600 600 600

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Average injection quantity mm3/st. 73.4 72.9 73.9

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 76.6 76.1 77.1

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 65.2 65.2 65.2

Oil temperature degC 48 46 50

Injection timing adjustment_04

Pump speed r/min 600 600 600

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Average injection quantity mm3/st. 73.4 72.4 74.4

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 76.6 75.6 77.6

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 66.2 66.2 66.2

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1800 1800 1800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 74.4 74.4 74.4

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 31.8 28.8 34.8

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2550 2550 2550

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

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 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 31.8 28.8 34.8

Difference in delivery mm3/st. 5.5

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 360 360 360

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 14.3 12.3 16.3

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 360 360 360

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 14.3 12.3 16.3

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. 105 105 145

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. 85 85 125

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_03

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 85 85 125

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_04

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 105 105 145

Oil temperature degC 48 46 50

Remarks
IDLE

Speed control lever angle

Pump speed r/min 360 360 360

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

0000000901

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Overflow quantity cm3/min 650 520 780

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 490 470 510

Pressure kgf/cm2 5 4.8 5.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 490 470 510

Pressure kgf/cm2 5 4.8 5.2

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 3.3 3.1 3.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 675 675 675

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 0.5 0.1 1.3

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 3.3 3.1 3.5

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 4.5 4.1 4.9

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 6.6 6.3 7

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 51 50 52

Timer stroke TA mm 2.4 2.2 2.6

Timer stroke variation dT mm 0.9 0.9 0.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 51 49.5 52.5

Timer stroke TA mm 2.4 2 2.8

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 35 33.5 36.5

Timer stroke TA mm 1.4 0.8 2

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 0.7 0.6 0.8

BCS stroke mm 2.4 2.2 2.6

Control lever angle alpha deg. 24 20 28

Control lever angle beta deg. 47 42 52

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjusting method [applied voltage Vi, dummy bolt (C)] 1. Hold the dummy bolt (C) against the control lever at position N = N1, Q = Q1. Fix using the lock nut. 2. When adjusting the potentiometer, position the control lever against the dummy bolt (C) and adjust the potentiometer so that the output voltage is V1 (V). 3. Remove the dummy bolt (C) after the completion of adjustment. Confirm that the potentiometer output voltage is within the above mentioned standards between the control lever's adjusting point and the idling position. N:Pump speed V:Output voltage Q:Injection quantity P:Boost pressure A:Adjusting point B:Checking point Q2:Idle Q3:Full speed (C): Dummy bolt (D): Bracket for mounting the dummy bolt (E): Part numbers of the dummy bolt and the nut 146526-3300 (bolt) 42L 013020-6040 (nut)
----------
N1=750r/min Q1=23.0+-1cm3/1,000st V1=4.48+-0.03V
----------
N1=750r/min N2=360r/min V1=4.48+-0.03V V2=1.90+-0.45V Q1=23.0+-1cm3/1,000st Q2=14.3+-2cm3/1,000st Idle P1=73.3kPa P2=550mmHg

0000001901 W-CSD ADJUSTMENT

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

----------
(B):TA=-0.0216t+1.21

0000002001 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. After adjusting the potentiometer, install the V-FICD and adjust the actuator rod so that the clearance between the control lever and the actuator rod is L1. 2. Apply P1{P2} negative pressure to the actuator. Confirm that the actuator moves through its full stroke.
----------
L=1+1mm P1=-53.3kPa P2=-400mmHg
----------
L=1+1mm

Information:

Utah
American Auto Parts
2575 South State St.
Salt Lake City, Utah 84115
Custom Muffler & Speed
335 North Main
Logan, Utah 84321
Diamond Automotive Machine
82 West Fifth So.
Provo, Utah 84601
Duchesne Auto & Industrial Supply
Main St.
Duchesne, Utah 84021
E & M Crankshaft & Valve Service
1884 South 900 West
Salt Lake City, Utah 84104
Felt Automotive Machine
Shop Inc.
2571 Lincoln
Ogden, Utah 84401
Floyd's Automotive
947 Folsom Ave.
Salt Lake City, Utah 84104
Larry Larson & Rand Tometich
91 Cross St.
Layton, Utah 84041
Midwest Service & Supply
4051 South Main
Salt Lake City, Utah 84107
Motor Service & Supply
30 W. Truman Ave.
Salt Lake City, Utah 84115
Paint & Piston Service Inc.
1343 Major Street
Salt Lake City, Utah 84115
Robinson's Auto Supply
3145 South Main
Salt Lake City, Utah 84115
Sharp Machine
68 West 12th Street
Ogden, Utah 84401
Steve's Specialty Service
900 East Center
Logan, Utah 84321
Temples Maschine Werkstadt
2900 South State
Salt Lake City, Utah 84115
Vermont
Central Automotive
201 Belmont Avenue
Bennington, Vermont 05201
Tri State Automotive Service
45 Elm St.
Brattleboro, Vermont 05201
Virginia
Auto Specialty Company
201 Cahill Court
Danville, Virginia 24541
C & C Automotive
8013 Centerville Rd.
Manassas, Virginia 22110
Chesapeake Equipment Co.
1540 Cedar Rd.
Chesapeake, Virginia 23320
Cline Automotive
9125 Jefferson Davis Hwy.
Richmond, Virginia 23234
H. L. White & Son.
502 Washington St.
Suffolk, Virginia 23434
Hoehns & Eanes Automotive
2226 Chamberlayne
Richmond, Virginia 23222
Hunt Auto Supply
7821 Military Hwy.
Norfolk, Virginia 23518
Kenson Automotive, Inc.
3801 Picket Rd.
Fairfax, Virginia 22030
Kinsey Electronic Balancing
409 Bullet Ave., S.E.
Roanoke, Virginia 24016
Midway Machine & Speed
Hwy. 11
Steeles Tavern, Virginia 24476
Miller's Auto Parts
426 West 24th Street
Norfolk, Virginia 23517
Motor Parts & Equipment
920 Riverside Rd.
Danville, Virginia 24543
R.C. Automotive
130 South Peyton
Alexandria, Virginia 22314
Sykes Auto Machine Inc.
1108 Queen St.
Alexandria, Virginia 22314
The Shop
701 Old Bermuda Hundred Rd.
Chester, Virginia 23831
Washington
A & W Bearing Service
925-12th Avenue
Seattle, Washington 98122
Al's Machine Shop
8412 East Sprague
Spokane, Washington 99206
B. F. Saulteren
1919 E. Sprague
Spokane, Washington 99202
B & G Machine
6245 Corson Street
Seattle, Washington 98108
D/B/A Genuine Parts Co.
E-8407 Sprague Ave.
Spokane, Washington 99206
Dudder Machine
211 Kirkland Ave.
Kirkland, Washington 98033
Earl's Machine Shop
628 S.W. 151st.
Seattle, Washington 98166
F & S Machine
2839 N. Taylor Rd.
Oak Harbor, Washington 98277
Green Service Company
915 Iowa St.
Bellingham, Washington 98225
Hegewald Inc.
701 West 11th
Vancouver, Washington 98660
Huston Auto Parts
423 W. Main St.
Chehalis, Washington 98532
Joe Bonners Place
320 S. Washington
Kennewick, Washington 99336
Johnson's Head & Engine Shop
4900 Lacey Blvd.
Lacey, Washington 98503
Kellogg Automotive Supply
1340 Vandercook Way
Longview, Washington 98623
L. Dennis Smythe Co.
18017 Third Ave. N.E.
Seattle, Washington 98155
Lake Auto Parts
6710 Kitsap Way
Bremerton, Washington 98310
Marten's Economy Auto Parts
11012 Pacific Ave.
Tacoma, Washington 98444
Nesbitt Auto Parts
315 East Champion
Bellingham, Washington 98225
Northeast Engine Service Center
707 Lucille
Seattle, Washington 98108
Pacific National Auto Parts
4001 Pacific Ave.
Tacoma, Washington 98408
Petersen Machine Works
7402 44th Ave. N.E.
Marysville, Washington 98270
Piston Service
1020 N. Wenatchee Dr.
Wenatchee, Washington 98801
Precision Engine Specialist
570 Mercer
Seattle, Washington 98109
Rainier Auto Parts, Inc.
4728 Rainier Ave. S.
Seattle, Washington 98118
West Virginia
Community Auto Parts
200 W. Stephens
Martinsburg, West Virginia 25401
Dalton's Automotive Machine Shop
Athens Star Route
Princeton, West Virginia 24740
Fitzgerald Engine Rebuilders
5650 Route 60 East
Huntington, West Virginia
Gordon Auto & Industrial Supply
Second & Cedar Streets
Moundsville, West Virginia 26041
Harold Givens Crankshaft
Service
302 Hunt Avenue
Charleston, West Virginia 25302
Jerry's Auto Service
1000 Pike
Grafton, W. Va. 26354
Wisconsin
Accurate Engine Modification
3437 North Burnum
Milwaukee, Wisconsin 53212
Automotive Sales & Service
56 North Main
Fond du Lac, Wisconsin 54935
Blakely Auto Parts
36 Third Street
Fond du Lac, Wisconsin 54935
Harbert Auto Parts
2011 63rd St.
Kenosha, Wisconsin 53140
Libert Motor Supply Co.
300 North Webster Ave.
Green Bay, Wisconsin 54301
McCummins Engine Service
Highway H
Lake Geneva, Wisconsin 53147
Mick's Auto Parts
2323 Eaton Lane
Racine, Wisconsin 53404
National Auto Electric
7526 W. Appleton Ave.
Milwaukee, Wisconsin 53216
Oshkosh Auto Parts Inc.
920 S. Main
Oshkosh, Wisconsin