Information injection-pump assembly
BOSCH
9 460 613 321
9460613321
ZEXEL
104742-7260
1047427260
Rating:
Components :
| 0. | INJECTION-PUMP ASSEMBLY | 104742-7260 |
| 1. | _ | |
| 2. | FUEL INJECTION PUMP | 104642-7260 |
| 3. | NUMBER PLATE | |
| 4. | _ | |
| 5. | CAPSULE | |
| 6. | ADJUSTING DEVICE | |
| 7. | NOZZLE AND HOLDER ASSY | |
| 8. | Nozzle and Holder | |
| 9. | Open Pre:MPa(Kqf/cm2) | |
| 10. | NOZZLE-HOLDER | |
| 11. | NOZZLE |
Include in #2:
104742-7260
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 460 613 321
9460613321
ZEXEL
104742-7260
1047427260
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
1600
1600
1600
Average injection quantity
mm3/st.
68.4
67.9
68.9
Difference in delivery
mm3/st.
6
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
39.4
33.4
45.4
Oil temperature
degC
48
46
50
Injection timing adjustment_03
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
38.9
32.9
44.9
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
45.3
40.8
49.8
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
1350
1350
1350
Average injection quantity
mm3/st.
64.4
59.9
68.9
Oil temperature
degC
50
48
52
Injection timing adjustment_06
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
68.4
67.4
69.4
Difference in delivery
mm3/st.
6
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_07
Pump speed
r/min
1925
1925
1925
Average injection quantity
mm3/st.
65.4
60.9
69.9
Oil temperature
degC
50
48
52
Injection quantity adjustment
Pump speed
r/min
2150
2150
2150
Average injection quantity
mm3/st.
5.2
2.2
8.2
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
52
50
54
Injection quantity adjustment_02
Pump speed
r/min
2300
2300
2300
Average injection quantity
mm3/st.
3
Oil temperature
degC
52
50
54
Injection quantity adjustment_03
Pump speed
r/min
2150
2150
2150
Average injection quantity
mm3/st.
5.2
0.7
9.7
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
52
50
54
Governor adjustment
Pump speed
r/min
338
338
338
Average injection quantity
mm3/st.
15
13
17
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
338
338
338
Average injection quantity
mm3/st.
15
12.5
17.5
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
85
65
105
Basic
*
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
85
65
105
Basic
*
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_03
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
85
65
105
Oil temperature
degC
48
46
50
Remarks
Full
Full
Speed control lever angle
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet ON at idling position and reversed operate
Magnet ON at idling position and reversed operate
Speed control lever angle_02
Pump speed
r/min
338
338
338
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet ON at idling position and reversed operate
Magnet ON at idling position and reversed operate
Speed control lever angle_03
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position and stop lever operate
Magnet OFF at idling position and stop lever operate
Speed control lever angle_04
Pump speed
r/min
338
338
338
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position and stop lever operate
Magnet OFF at idling position and stop lever operate
0000000901
Pump speed
r/min
1050
1050
1050
Overflow quantity
cm3/min
1280
1050
1510
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
1050
1050
1050
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
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
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
1925
1925
1925
Pressure
kPa
706
667
745
Pressure
kgf/cm2
7.2
6.8
7.6
Oil temperature
degC
50
48
52
0000001101
Pump speed
r/min
1050
1050
1050
Timer stroke
mm
0.8
0.6
1
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
1050
1050
1050
Timer stroke
mm
0.8
0.4
1.2
Basic
*
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1925
1925
1925
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
Reverse operation (At Normal: OFF, At Stop: ON) V 13 12 14
Reverse operation (At Normal: OFF, At Stop: ON) V 13 12 14
Timing setting
K dimension
mm
3.6
3.5
3.7
KF dimension
mm
5.54
5.44
5.64
MS dimension
mm
0.9
0.8
1
Pre-stroke
mm
0.2
0.18
0.22
Control lever angle alpha
deg.
25
21
29
Control lever angle beta
deg.
38.5
33.5
43.5
Test data Ex:
0000001801 Temp. adjust full-load screw
Temporary full load screw adjustment
Set the full load screw protrusion at L mm at assembly.
----------
L=14+-0.5mm
----------
L=14+-0.5mm
----------
L=14+-0.5mm
----------
L=14+-0.5mm
0000001901 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+0.09mm R=35mm
----------
N=338r/min Q=0mm3/st T=6~9N-m(0.6~0.9kgf-m) L=2mm M=4.0kg
----------
S=Dia6.5+0.09mm R=35mm
Information:
Flangeless Liners
(1) Outside diameter of cylinder liner ... 103.28 to 103.30 mm (4.066 to 4.067 in)(2) Inside diameter of cylinder liner ... 98.48 to 98.50 mm (3.877 to 3.878 in) Maximum diameter wear (when boring or new liners are needed) ... 0.20 mm (0.008 in)Interference fit of liner in cylinder block ... 0.08 to 0.13 mm (0.003 to 0.005 in)Length of cylinder liner ... 228.73 to 228.98 mm (9.005 to 9.015 in)Maximum cylinder liner can be bored (made larger than original size) ... 0.76 mm (0.030 in) The 4.236 flangeless cylinder liners are the only ones that can be bored. All other liners must be replaced when worn beyond specifications.(3) Liner projection (height of liner above face of cylinder block) ... 0.71 to 0.94 mm (0.028 to 0.037 in)(4) Diameter of parent bore in cylinder block for liner ... 103.162 to 103.188 mm (4.0615 to 4.0625 in)Flanged Liners
New cylinder blocks have been introduced on the 4.236 engine. The 4.236 engine has a larger cylinder liner parent bore diameter and the outside diameter of the cylinder liner is also larger. The liners will no longer have a flame ring. Effective with this change only flanged liners will be available. The change became effective at engine serial number LDU106654N and up. See General Information in Systems Operation for the serial number location.(1) Outside diameter of cylinder liner.Earlier engines with thin wall liners: Production liner ... 103.238 to 103.264 mm (4.0645 to 4.0655 in)Service liner ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners: Production liner ... 104.254 to 104.280 mm (4.1045 to 4.1055 in)Service liner ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)(2) Inside diameter of cylinder liner: Production liner ... 98.48 to 98.50 mm (3.877 to 3.878 in)Service liner ... 98.50 to 98.53 mm (3.878 to 3.879 in)Maximum diameter wear (when new liners are needed ... 0.20 mm (0.008 in)Transition fit of service liner in cylinder block ... 0.03 mm ( 0.001 in)Length of cylinder liner with flame ring ... 227.10 to 227.43 mm (8.941 to 8.954 in)Length of cylinder liner without flame ring ... 226.03 to 226.82 mm (8.899 to 8.930 in)(3) Liner (flange) projection [do not measure from flame ring (if equipped)] ... 0.10 mm (0.004 in) above to 0.10 mm (0.004 in) below face of cylinder block. Flange thickness of cylinder liner ... 3.81 to 3.86 mm (0.150 to 0.152 in)(4) Diameter of parent bore in cylinder block in liner: Earlier engines with thin wall liners ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)Depth of recess for cylinder liner flange ... 3.81 to 3.91 mm (0.150 to 0.154 in)All Engine Blocks
(5) Diameter of bore in cylinder block for camshaft No. 1 front bearing [has only front bearing (6)] ...
(1) Outside diameter of cylinder liner ... 103.28 to 103.30 mm (4.066 to 4.067 in)(2) Inside diameter of cylinder liner ... 98.48 to 98.50 mm (3.877 to 3.878 in) Maximum diameter wear (when boring or new liners are needed) ... 0.20 mm (0.008 in)Interference fit of liner in cylinder block ... 0.08 to 0.13 mm (0.003 to 0.005 in)Length of cylinder liner ... 228.73 to 228.98 mm (9.005 to 9.015 in)Maximum cylinder liner can be bored (made larger than original size) ... 0.76 mm (0.030 in) The 4.236 flangeless cylinder liners are the only ones that can be bored. All other liners must be replaced when worn beyond specifications.(3) Liner projection (height of liner above face of cylinder block) ... 0.71 to 0.94 mm (0.028 to 0.037 in)(4) Diameter of parent bore in cylinder block for liner ... 103.162 to 103.188 mm (4.0615 to 4.0625 in)Flanged Liners
New cylinder blocks have been introduced on the 4.236 engine. The 4.236 engine has a larger cylinder liner parent bore diameter and the outside diameter of the cylinder liner is also larger. The liners will no longer have a flame ring. Effective with this change only flanged liners will be available. The change became effective at engine serial number LDU106654N and up. See General Information in Systems Operation for the serial number location.(1) Outside diameter of cylinder liner.Earlier engines with thin wall liners: Production liner ... 103.238 to 103.264 mm (4.0645 to 4.0655 in)Service liner ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners: Production liner ... 104.254 to 104.280 mm (4.1045 to 4.1055 in)Service liner ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)(2) Inside diameter of cylinder liner: Production liner ... 98.48 to 98.50 mm (3.877 to 3.878 in)Service liner ... 98.50 to 98.53 mm (3.878 to 3.879 in)Maximum diameter wear (when new liners are needed ... 0.20 mm (0.008 in)Transition fit of service liner in cylinder block ... 0.03 mm ( 0.001 in)Length of cylinder liner with flame ring ... 227.10 to 227.43 mm (8.941 to 8.954 in)Length of cylinder liner without flame ring ... 226.03 to 226.82 mm (8.899 to 8.930 in)(3) Liner (flange) projection [do not measure from flame ring (if equipped)] ... 0.10 mm (0.004 in) above to 0.10 mm (0.004 in) below face of cylinder block. Flange thickness of cylinder liner ... 3.81 to 3.86 mm (0.150 to 0.152 in)(4) Diameter of parent bore in cylinder block in liner: Earlier engines with thin wall liners ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)Depth of recess for cylinder liner flange ... 3.81 to 3.91 mm (0.150 to 0.154 in)All Engine Blocks
(5) Diameter of bore in cylinder block for camshaft No. 1 front bearing [has only front bearing (6)] ...