Information injection-pump assembly
BOSCH
9 460 613 933
9460613933
ZEXEL
104741-7111
1047417111
Rating:
Cross reference number
BOSCH
9 460 613 933
9460613933
ZEXEL
104741-7111
1047417111
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
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
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
Right R
Injection timing adjustment
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
72.7
72.2
73.2
Difference in delivery
mm3/st.
6
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
45.4
41.4
49.4
Oil temperature
degC
48
46
50
Injection timing adjustment_03
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
70.7
66.7
74.7
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
72.7
71.7
73.7
Difference in delivery
mm3/st.
6
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
68
65.5
70.5
Oil temperature
degC
50
48
52
Injection quantity adjustment
Pump speed
r/min
1425
1425
1425
Average injection quantity
mm3/st.
13.5
9.5
17.5
Difference in delivery
mm3/st.
4
Basic
*
Oil temperature
degC
50
48
52
Injection quantity adjustment_02
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
3
Oil temperature
degC
50
48
52
Injection quantity adjustment_03
Pump speed
r/min
1425
1425
1425
Average injection quantity
mm3/st.
13.5
9
18
Difference in delivery
mm3/st.
4
Basic
*
Oil temperature
degC
50
48
52
Governor adjustment
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
11.1
9.1
13.1
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
11.1
8.6
13.6
Basic
*
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
86.5
81.5
91.5
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
86.5
81.5
91.5
Oil temperature
degC
48
46
50
Remarks
Full
Full
Speed control lever angle
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
0000000901
Pump speed
r/min
1300
1300
1300
Overflow quantity
cm3/min
380
250
510
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
1300
1300
1300
Pressure
kPa
471
451
491
Pressure
kgf/cm2
4.8
4.6
5
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_02
Pump speed
r/min
1300
1300
1300
Pressure
kPa
471
442
500
Pressure
kgf/cm2
4.8
4.5
5.1
Basic
*
Oil temperature
degC
50
48
52
0000001101
Pump speed
r/min
1300
1300
1300
Timer stroke
mm
1.6
1.4
1.8
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
1100
1100
1100
Timer stroke
mm
0.5
0
1
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1300
1300
1300
Timer stroke
mm
1.6
1.3
1.9
Basic
*
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
1425
1425
1425
Timer stroke
mm
3.3
2.6
3.8
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
4.9
5.1
MS dimension
mm
1.7
1.6
1.8
Pre-stroke
mm
0.45
0.43
0.47
Control lever angle alpha
deg.
16
12
20
Control lever angle beta
deg.
32
27
37
Test data Ex:
0000001801 STARTING I/Q ADJUSTMENT
Starting Q decrease lever adjustment
Adjust using the screw (A) so that the standards are satisfied, then fix using the nut (B).
Screw (B) protrusion: L
(C) = Cap
(D) = Stop lever
----------
L=7.4~11.1mm
----------
L=7.4~11.1mm T=6~9Nm(0.6~0.9kgfm)
----------
L=7.4~11.1mm
----------
L=7.4~11.1mm T=6~9Nm(0.6~0.9kgfm)
Information:
Introduction
Tools are now available for the 6V4830 Fixture Group for removal and replacement of tappet springs on 3500 Unit Injectors.
Type 2 Fuel Injector. (1) Spring. (2) Rack Bar.
(3) 6V4830 Fixture Group. (4) 4C9279 Plate Assembly.Use fixture group (3) and plate assembly (4) along with the procedure in this instruction to remove and install tappet springs on injectors.Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.Removal and Installation of Fuel Injector Tappet Springs
Take care not to damage, drop, or jar the internal parts of the injector. Injector parts must be clean when reassembled. Place a light coating of clean diesel fuel, kerosene, or calibration fluid on the moving internal components during assembly.
* Clean the outside of the injector before disassembly. Install good O-ring seals on the injector and then install a 6V4172 Cleaning Sleeve. Wash the outside of the injector with solvents and a brush. Dry with pressure air.
Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes.The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.
1. Remove existing plate and secure plate assembly (4) to fixture group (3).2. Remove O-ring seals from the injector prior to placing injector into fixture.3. Place injector into fixture with spring up as shown. Rack bar (2) on injector is to be extended out so that it is locked into position by two pins on plate assembly (4). 4. Using the handle of the fixture group, compress injector spring (tappet) (5) so that lock pin (6) can be pushed IN to release the tappet assembly from the injector body. 5. Remove tappet assembly from the injector body. Remove and discard old spring. Place the injector plunger on a soft clean cloth to avoid handling the plunger. Excessive handling will remove the fuel on the plunger and may result in corroding the plunger if it is left out for an extended period of time.6. Install new spring on injector body. 7. Locate the punched dot (.)(7) on the top end of the gear after it is pulled out of the body. Using a yellow magic marker, paint the whole length of the tooth that is 180° opposite the punched dot.
Injector Assembly (shown without spring).8. As the tappet/plunger assembly is inserted into the body, the yellow colored tooth on the gear should be visible in the center of the slot for the tappet lock pin.
Injector Assembly (shown without spring). 9. With the colored tooth visible in the slot of the injector body, a pin or long narrow screw driver is needed to position the gear to engage rack and pinion teeth after which the tappet assembly will drop into place.10. Using the 6V4830 Fixture Group, apply pressure on tappet (5) to compress the spring so the pin pops out and locks the tappet assembly in place.11. Remove the injector from the fixture. Push and pull the
Tools are now available for the 6V4830 Fixture Group for removal and replacement of tappet springs on 3500 Unit Injectors.
Type 2 Fuel Injector. (1) Spring. (2) Rack Bar.
(3) 6V4830 Fixture Group. (4) 4C9279 Plate Assembly.Use fixture group (3) and plate assembly (4) along with the procedure in this instruction to remove and install tappet springs on injectors.Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.Removal and Installation of Fuel Injector Tappet Springs
Take care not to damage, drop, or jar the internal parts of the injector. Injector parts must be clean when reassembled. Place a light coating of clean diesel fuel, kerosene, or calibration fluid on the moving internal components during assembly.
* Clean the outside of the injector before disassembly. Install good O-ring seals on the injector and then install a 6V4172 Cleaning Sleeve. Wash the outside of the injector with solvents and a brush. Dry with pressure air.
Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes.The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.
1. Remove existing plate and secure plate assembly (4) to fixture group (3).2. Remove O-ring seals from the injector prior to placing injector into fixture.3. Place injector into fixture with spring up as shown. Rack bar (2) on injector is to be extended out so that it is locked into position by two pins on plate assembly (4). 4. Using the handle of the fixture group, compress injector spring (tappet) (5) so that lock pin (6) can be pushed IN to release the tappet assembly from the injector body. 5. Remove tappet assembly from the injector body. Remove and discard old spring. Place the injector plunger on a soft clean cloth to avoid handling the plunger. Excessive handling will remove the fuel on the plunger and may result in corroding the plunger if it is left out for an extended period of time.6. Install new spring on injector body. 7. Locate the punched dot (.)(7) on the top end of the gear after it is pulled out of the body. Using a yellow magic marker, paint the whole length of the tooth that is 180° opposite the punched dot.
Injector Assembly (shown without spring).8. As the tappet/plunger assembly is inserted into the body, the yellow colored tooth on the gear should be visible in the center of the slot for the tappet lock pin.
Injector Assembly (shown without spring). 9. With the colored tooth visible in the slot of the injector body, a pin or long narrow screw driver is needed to position the gear to engage rack and pinion teeth after which the tappet assembly will drop into place.10. Using the 6V4830 Fixture Group, apply pressure on tappet (5) to compress the spring so the pin pops out and locks the tappet assembly in place.11. Remove the injector from the fixture. Push and pull the