104742-7163 ZEXEL 9 460 614 975 BOSCH INJECTION-PUMP ASSEMBLY 9460614975 1047427163 12969351950

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 975 9460614975

ZEXEL 104742-7163 1047427163

YANMAR 12969351950 12969351950

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Cross reference number

BOSCH 9 460 614 975 9460614975

ZEXEL 104742-7163 1047427163

YANMAR 12969351950 12969351950

Zexel num

Bosch num

Firm num

Name

104742-7163

9 460 614 975

12969351950 YANMAR

INJECTION-PUMP ASSEMBLY
4JH3 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. 58.7 58.2 59.2

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. 69.3 68.8 69.8

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. 33.7 33.7 33.7

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. 43.2 43.2 43.2

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. 58.7 57.7 59.7

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. 69.3 68.3 70.3

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. 73.3 68.3 78.3

Oil temperature degC 50 48 52

Injection timing adjustment_09

Pump speed r/min 1800 1800 1800

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 82.8 77.8 87.8

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2050 2050 2050

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 10.6 6.1 15.1

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2100 2100 2100

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 2050 2050 2050

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 10.6 5.6 15.6

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 300 300 300

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 20.6 18.6 22.6

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 300 300 300

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 20.6 18.1 23.1

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. 79.2 59.2 99.2

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. 79.2 59.2 99.2

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 300 300 300

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 300 300 300

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 50 48 52

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 1800 1800 1800

Boost pressure kPa 66.7 65.4 68

Boost pressure mmHg 500 490 510

Pressure kPa 667 628 706

Pressure kgf/cm2 6.8 6.4 7.2

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 1800 1800 1800

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 16 16 16

Test voltage V 25 24 26

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. 38 33 43

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=300r/min Q=0mm3/st T=6~9N-m(0.6~0.9kgf-m) L=2mm M=4.0kg
----------
S=Dia6.50+0.09mm R=35mm

Information:

1. Remove the bolts (2) that hold suction bell and tubes (1) to the engine block. 2. Remove O-ring seals (3) from the tubes. Inspect O-ring seals for damage. Make a replacement if necessary. 3. Remove clip (5) and then remove screen (4). Clean the screen if necessary. 4. Remove the bolts (7) that hold the oil pump to the engine block. Remove oil pump (6).Install Oil Pump
1. Put the oil pump (1) in position on the engine block and install the bolts that hold it. 2. Install screen (2) with the clip (3) that holds it. 3. Put a small amount of clean oil on O-ring seals (4). Install the O-ring seals on the tubes. 4. Put tubes (5) in position in the oil pump.5. Put suction bell (6) and support in position on the engine block and install the four bolts that hold it.End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump 1. Remove bolts (1) and cover (2). Remove spacer from cover, then remove spring and plunger from pump bore. 2. Remove bolt (4), washer (3) and gear (5) from the pump. 3. Remove bolts (7) then remove shaft assembly (6) from the pump. 4. Remove bolts (8) then remove cover assembly (9) from the pump body. 5. Use Tooling (A) to remove bearings (10) from cover assembly (9). 6. Remove shaft and gear assembly (11) from the pump body. 7. Remove bolt and washer from gear (12). Use Tool (B) to remove gear (12) 8. Remove shaft and gear assembly (13) from the pump body. 9. Use Tooling (A) to remove bearings from pump body bore.Assemble Oil Pump
1. Use Tooling (A) to install bearings (2) until they are even with the outside surface of main pump body (1). Install bearings (2) so the junctions in the bearings are 30 15 degrees from the center line of the bearing bores and toward the oil pump outlet passage as shown. 2. Install shaft and gear assembly (3) in the pump body. Install key in shaft. 3. Install gear (4) on the shaft. Install bolt and washer on the shaft. 4. Install shaft and gear assembly (5) in the pump body. 5. Install bearings (7) in the cover assembly (6) with Tooling (A). Install the bearings until they are in position the same distance in from each side of the cover assembly. Install the bearings with the oil holes in the bearings in alignment with the oil holes in the cover assembly and the junctions in the bearings in alignment with the cavity in the cover assembly. 6. Install cover assembly (6) on the pump body. 7. Install shaft assembly (8) on the oil pump body with the two bolts that hold it. 8. Install gear (9) on shaft assembly. Install washer and bolt on gear (9). 9. Install plunger (10), spring (13) and spacer (11) in the pump body. Install cover (12) and the bolts (14) that hold it.End By:a. install oil pump