104742-7133 ZEXEL 9 460 614 973 BOSCH INJECTION-PUMP ASSEMBLY 9460614973 1047427133 12969851900

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 973 9460614973

ZEXEL 104742-7133 1047427133

YANMAR 12969851900 12969851900

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Cross reference number

BOSCH 9 460 614 973 9460614973

ZEXEL 104742-7133 1047427133

YANMAR 12969851900 12969851900

Zexel num

Bosch num

Firm num

Name

104742-7133

9 460 614 973

12969851900 YANMAR

INJECTION-PUMP ASSEMBLY
4JH3-DTZ 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 950 950 950

Boost pressure kPa 24 22.7 25.3

Boost pressure mmHg 180 170 190

Average injection quantity mm3/st. 61.7 61.2 62.2

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 950 950 950

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 73.2 72.7 73.7

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 30 30

Oil temperature degC 48 46 50

Injection timing adjustment_04

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 39.4 39.4 39.4

Oil temperature degC 48 46 50

Injection timing adjustment_05

Pump speed r/min 950 950 950

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 44.6 44.6 44.6

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 950 950 950

Boost pressure kPa 24 22.7 25.3

Boost pressure mmHg 180 170 190

Average injection quantity mm3/st. 61.7 60.7 62.7

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_07

Pump speed r/min 950 950 950

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 73.2 72.2 74.2

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_08

Pump speed r/min 1330 1330 1330

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 76.3 71.3 81.3

Oil temperature degC 50 48 52

Injection timing adjustment_09

Pump speed r/min 1900 1900 1900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 86 81 91

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2150 2150 2150

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 11.2 6.7 15.7

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2250 2250 2250

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 5

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2150 2150 2150

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 11.2 6.2 16.2

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 338 338 338

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 20.2 18.2 22.2

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 338 338 338

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 20.2 17.7 22.7

Difference in delivery mm3/st. 3

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. 87.3 67.3 107.3

Basic *

Oil temperature degC 48 46 50

Remarks
Full

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. 87.3 67.3 107.3

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 338 338 338

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

Speed control lever angle_02

Pump speed r/min 338 338 338

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 ON at idling position and stop lever operate

0000000901

Pump speed r/min 1050 1050 1050

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Overflow quantity cm3/min 395 265 525

Oil temperature degC 52 50 54

Stop lever angle

Pump speed r/min 1050 1050 1050

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure kPa 510 481 539

Pressure kgf/cm2 5.2 4.9 5.5

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 950 950 950

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure kPa 490 451 529

Pressure kgf/cm2 5 4.6 5.4

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1050 1050 1050

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure kPa 510 471 549

Pressure kgf/cm2 5.2 4.8 5.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1900 1900 1900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure kPa 677 638 716

Pressure kgf/cm2 6.9 6.5 7.3

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1050 1050 1050

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke mm 0.8 0.6 1

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1050 1050 1050

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke mm 0.8 0.4 1.2

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1900 1900 1900

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Timer stroke mm 1.7 1.2 2.1

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 3.6 3.5 3.7

KF dimension mm 6.85 6.75 6.95

MS dimension mm 0.9 0.8 1

BCS stroke mm 4.5 4.4 4.6

Pre-stroke mm 0.2 0.18 0.22

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 41 36 46

Test data Ex:

0000001801 STOP LEVER ADJUSTMENT

Adjustment of the stop lever 1. Confirm that the starting injection quantity is within standards at the normal position. If below the specified lower limit, move the stop lever serrations one tooth and reconfirm. 2. Pull the stop lever (A) to the fuel cut direction at the standard idling speed of N and adjust the screw (B) to the position Q. Fix nut (C) to the torque T at the position where the clearance between the stop lever and the end of the screw is L mm (the screw is returned 2 turns). The head of the screw must protrude above the face of the nut. If the head of the screw is below the face of the nut, adjust the clearance between the stop lever A and the end of the screw at Q to L mm or more. 3. If adjustment in item 2 is not possible, move the stop lever installation position 1 tooth. 4. The stop lever's operating force is max. M kg (at R = 35). The stop lever must operate smoothly. (D) Normal position (E) Stop position
----------
N=338r/min Q=0mm3/st T=6~9N-m(0.6~0.9kgf-m) L=2mm M=4.0kg
----------
S=Dia6.5+0.09-0mm R=35mm

Information:

Start By:a. remove timing gear coverb. remove push rods and valve lifters 1. Remove air compressor outlet hose (1). (Not applicable).2. Remove air compressor air inlet tube (3). (Not applicable).3. Remove air compressor coolant outlet tube (4). (Not applicable)4. Remove turbocharger oil return tube (2). 5. Use Tooling (A) to remove studs (5).6. Turn the flywheel with Tool (B), and remove each bolt (6) as it becomes accessible.7. Turn the flywheel with Tool (B) until the "V" marks on the front timing gears are in alignment.8. Install Tooling (C) through the holes for studs (5) into camshaft rear gear (7).
Tooling (C) must be used to prevent the loss of rear balance weight timing and to keep the camshaft rear gear in place when the camshaft is removed.
9. Tighten Tooling (C) evenly to remove the camshaft rear gear from the camshaft. 10. Remove thrust plate (8).
Be careful not to damage the camshaft bearings. Do not pry the camshaft out of the cylinder block. If resistance to camshaft removal occurs, turn the camshaft so the lobes will align the bearing journals with the camshaft bearing bores.
11. Carefully remove the camshaft and gear (9) from the cylinder block.12. If removal of the camshaft gear is necessary, place the camshaft and gear in a hydraulic press. Place Tool (D) over the camshaft, and press against it to remove the camshaft from the gear.
Be careful not to scratch or mar the finished surfaces of the camshaft.
13. Remove the key from the camshaft.14. If dowel removal is necessary, use Tool (E) to remove the dowel.Install Camshaft
1. Install the key in the camshaft. Be sure the key is seated in the camshaft.2. Install the pin in the rear of the camshaft. Install the pin to a height of 8.51 to 9.01 mm (.335 to .355 in).3. Heat the camshaft drive gear to a maximum temperature of 204° C (400° F), align the groove in the drive gear with the key in the camshaft, and install the camshaft drive gear with the timing marks away from the camshaft.4. Put clean engine oil on the camshaft bearing journals and lobes.5. Carefully install the camshaft into the cylinder block. Do not force the camshaft into position. If resistance to camshaft installation occurs, turn the camshaft so the lobes will align the bearing journals with the camshaft bearing bores. 6. Align the "V" marks on camshaft drive gear (2) and idler gear (3).7. Install thrust plate (1) to hold the camshaft and camshaft drive gear (2) in the cylinder block. 8. Loosen the bolts Tool (B) that hold camshaft rear gear (5) so camshaft rear gear (5) will engage the dowel on the rear of the camshaft.9. After the dowel is engaged, remove Tool (B), and install bolts (4).10. Use Tool (A) to turn the flywheel, and install each of four bolts (4). Tighten bolts (4) to a torque of 23 to 31 N m (17 to 23 lb ft).11. Put 5P-3413 Pipe Sealant with "Teflon" on the