104742-7100 ZEXEL 9 460 614 495 BOSCH INJECTION-PUMP ASSEMBLY 9460614495 1047427100 12990351500

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 495 9460614495

ZEXEL 104742-7100 1047427100

YANMAR 12990351500 12990351500

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Cross reference number

BOSCH 9 460 614 495 9460614495

ZEXEL 104742-7100 1047427100

YANMAR 12990351500 12990351500

Zexel num

Bosch num

Firm num

Name

104742-7100

9 460 614 495

12990351500 YANMAR

INJECTION-PUMP ASSEMBLY
4TNE98 * 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 850 850 850

Average injection quantity mm3/st. 65 64.5 65.5

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 58.7 58.7 58.7

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 65 64 66

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 62.7 62.7 62.7

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 35.5 31 40

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Injection quantity adjustment_02

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 35.5 30.5 40.5

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Injection quantity adjustment_03

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 5

Oil temperature degC 50 48 52

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 23 21 25

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 23 20.5 25.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 76 71 81

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 76 71 81

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF

0000000901

Pump speed r/min 1000 1000 1000

Overflow quantity cm3/min 410 280 540

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1000 1000 1000

Pressure kPa 490 461 519

Pressure kgf/cm2 5 4.7 5.3

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Pressure kPa 490 451 529

Pressure kgf/cm2 5 4.6 5.4

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1200 1200 1200

Pressure kPa 539 500 578

Pressure kgf/cm2 5.5 5.1 5.9

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1000 1000 1000

Timer stroke mm 1.6 1.4 1.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 1000 1000

Timer stroke mm 1.6 1.2 2

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1200 1200 1200

Timer stroke mm 2.7 2.1 3.3

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 16 16 16

Test voltage V 25 24 26

Timing setting

K dimension mm 3.1 3 3.2

KF dimension mm 5.3 5.2 5.4

MS dimension mm 2 1.9 2.1

Control lever angle alpha deg. 16 12 20

Control lever angle beta deg. 35 30 40

Test data Ex:

0000001801 STOP LEVER ADJUSTMENT

Adjustment of the stop lever Adjust adjusting bolt (B) so that the starting injection quantity is within the standard. Fix using nut. (A) Adjusting nut (C) Starting injection quantity adjusting lever
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L=15.0~18.5mm

Information:

1. Remove plug (1) from the fuel injection pump housing.2. Use Tool (D) to loosen nut (2) for the fuel injection pump to be removed. Disconnect the fuel injection line nuts, and remove the felt washer. 3. Install Tool (A) in the fuel pump housing as shown with the square end down. Use a small amount of hand force to push down on Tool (A) while the control lever is moved forward to the "FUEL ON" position. Rack travel will stop in the center (zero) position. Hold a light forward force on the governor control lever to keep the fuel racks in the center (zero) position.4. Use Tool (B) to remove bushing (3) from the fuel injection pump housing. 5. Remove bushing (3) and O-ring seal (4).
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed in their original location.
6. Use Tool (C) to remove fuel injection pump (5). 7. Remove spacer (6) from the fuel injection pump housing. Make a note of the position from which each spacer was removed so each spacer can be installed in its original position.
Be careful when the fuel injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. The check assemblies are made as a set. Do not mix the parts of the different check assemblies. Do not remove or make any adjustments of the gear segment on the plunger. It has been preset at the factory. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
8. Disassemble the fuel injection pump as follows: Remove ring (7). Separate bonnet (10) from barrel (9). Remove the spring and the check assembly from the bonnet. Remove plunger (8), the washer and spring from barrel (9).Install Fuel Injection Pumps
1. Inspect all parts for wear or damage. The plunger and barrel are serviced only as an assembly. 2. Put clean diesel fuel on plunger (1). Put plunger (1), washer (6) and spring (2) in position on barrel (3).3. Put check valve assembly (7) and spring (8) in bonnet (9). Connect bonnet (9) and barrel (3) together with ring (4). 4. Put spacer (10) into position in the pump housing bore. Be sure the correct spacer is with each pump. 5. Note the location of dowels (11) and (12) in the fuel injection pump housing. These dowels are for alignment of the fuel injection pump. 6. Slot (13) in gear segment (5) must align with dowel (11).7. Groove (14) must engage with dowel (12). 8. Use Tool (A) to put the fuel racks in the center (zero) position. See Remove Fuel Injection Pumps.9. Use Tool