104741-7250 ZEXEL 9 460 614 475 BOSCH INJECTION-PUMP ASSEMBLY 9460614475 1047417250

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 475 9460614475

ZEXEL 104741-7250 1047417250

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Cross reference number

BOSCH 9 460 614 475 9460614475

ZEXEL 104741-7250 1047417250

Zexel num

Bosch num

Firm num

Name

104741-7250

9 460 614 475

TATA

INJECTION-PUMP ASSEMBLY
JX493ZQ * 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)
Left L

Injection timing adjustment

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 26.2 25.7 26.7

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 800 800 800

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 43 42.5 43.5

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1150 1150 1150

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 70.4 69.9 70.9

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 26.2 25.2 27.2

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 800 800 800

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 43 42 44

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 1150 1150 1150

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 70.4 69.4 71.4

Difference in delivery mm3/st. 6.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 1500 1500 1500

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 79.1 74.1 84.1

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. 81.1 77.1 85.1

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 21.8 18.8 24.8

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2400 2400 2400

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 5

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2100 2100 2100

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Average injection quantity mm3/st. 21.8 18.8 24.8

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 11.2 9.2 13.2

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 mmHg 0 0 0

Average injection quantity mm3/st. 11.2 9.2 13.2

Difference in delivery mm3/st. 2

Basic *

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. 97.2 77.2 117.2

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. 97.2 77.2 117.2

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 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 1500 1500 1500

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Overflow quantity with S/T ON cm3/min 495 365 625

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1500 1500 1500

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Pressure with S/T OFF kPa 608 579 637

Pressure with S/T OFF kgf/cm2 6.2 5.9 6.5

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1500 1500 1500

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Pressure with S/T OFF kPa 608 579 637

Pressure with S/T OFF kgf/cm2 6.2 5.9 6.5

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1500 1500 1500

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Timer stroke with S/T OFF mm 2.3 2.1 2.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1150 1150 1150

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 1400 1400 1400

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Timer stroke with S/T OFF mm 1.3 0.9 1.7

Oil temperature degC 50 48 52

_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Timer stroke with S/T OFF mm 2.3 2.1 2.5

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 1900 1900 1900

Boost pressure kPa 93.3 92 94.6

Boost pressure mmHg 700 690 710

Timer stroke with S/T OFF mm 4.8 4.3 5.2

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 3.1 3 3.2

KF dimension mm 5.5 5.4 5.6

MS dimension mm 0.9 0.8 1

BCS stroke mm 3.7 3.5 3.9

Pre-stroke mm 0.2 0.18 0.22

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 37 32 42

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Adjusting method [applied voltage 10 V, dummy bolt (A)] 1. Hold the dummy bolt (A) against the control lever at position N = N1, Q = Q1. Fix using the lock nut. 2. When adjusting the potentiometer, position the control lever to contact the dummy bolt (A). Adjust the potentiometer so that the output voltage V is V1. 3. Remove the dummy bolt (A) 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 B:Adjusting point C:Checking point Vi:Applied voltage Q2 = idle lever position Q3 = full speed lever position
----------
N1=600r/min Q1=14.4+-1.0cm3/1,000st V1=1.98+-0.03V Vi=10V
----------
N1=600r/min Q1=14.4+-1.0cm3/1,000st V1=1.98+-0.03V P1=0kPa P2=0mmHg N2=-r/min N3=-r/min Q2=Idle V2=(1.2+-0.45)V V3=(7.37+-0.83)V Q3=Full speed

Information:

Start By:a. remove rocker shaft and push rods 1. Remove circlip (1) and the washer from each end of the rocker shaft. 2. Put identification marks on the rocker arms, brackets and springs as to their location on the rocker shaft. Remove rocker arms (2), brackets (3) and springs (4) from each side of the rocker shaft.3. Remove screw (5) and rocker shaft oil feed connection (6). 4. Remove nut (7) and adjusting screw (8) from the rocker arm.5. Measure the bore of the bearings in each of the rocker arms. The bore must be 19.06 to 19.10 mm (.7505 to .7520 in.).6. Measure the diameter of the rocker shaft at each of the rocker arm locations. The diameter must be 19.01 to 19.04 mm (.7485 to .7495 in.). The maximum permissible clearance between the rocker arm bearings and shaft is 0.13 mm (.005 in.).7. If a replacement is needed, remove bushing (9) with tooling (A) and a press.Assemble Rocker Shaft
1. If a replacement was needed, make an alignment of oil hole (1) in the bushing with the oil hole in the rocker arm. Install new bushing (3) in the rocker arm with tooling (A) and a press. Check the bore dimension of the bushing in the rocker arm after installation. It must be 19.06 to 19.10 mm (.7505 to .7520 in.).
Do not turn the adjusting screw too far into the rocker arms. Damage to the valve can be the result after the rocker shaft and push rods have been installed in the engine.
2. Install adjusting screw (4) and nut (2) in the rocker arm. 3. Slide oil feed connection (9) on the rocker shaft. Install bolt (5) that holds it in place.4. Install springs (6), brackets (7) and rocker arms (8) in their original positions. 5. Install washer (11) and circlip (10) on each end of the rocker shaft.End By:a. install rocker shaft and push rods