104742-7440 ZEXEL 9 460 614 925 BOSCH INJECTION-PUMP ASSEMBLY 9460614925 1047427440 12991751100

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 925 9460614925

ZEXEL 104742-7440 1047427440

YANMAR 12991751100 12991751100

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Cross reference number

BOSCH 9 460 614 925 9460614925

ZEXEL 104742-7440 1047427440

YANMAR 12991751100 12991751100

Zexel num

Bosch num

Firm num

Name

104742-7440
104742-7441

9 460 614 925

12991751100 YANMAR

INJECTION-PUMP ASSEMBLY
4TNE92 * K 11CJ VE4 VE

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

(Solenoid timer adjustment condition) OFF

Injection timing adjustment

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 41.3 40.8 41.8

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 40.6 35.1 46.1

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 41.3 40.3 42.3

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1025 1025 1025

Average injection quantity mm3/st. 41.8 41.8 41.8

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 1225 1225 1225

Average injection quantity mm3/st. 13.7 9.2 18.2

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Injection quantity adjustment_02

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 5

Oil temperature degC 50 48 52

Injection quantity adjustment_03

Pump speed r/min 1225 1225 1225

Average injection quantity mm3/st. 13.7 8.7 18.7

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Governor adjustment

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 7.4 5.4 9.4

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 7.4 4.9 9.9

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. 55.5 50.5 60.5

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 55.5 50.5 60.5

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 425 425 425

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 1000 1000 1000

Overflow quantity with S/T ON cm3/min 490 360 620

Oil temperature degC 50 48 52

Remarks
With an O-ring

Stop lever angle

Pump speed r/min 1000 1000 1000

Pressure with S/T ON kPa 549 510 588

Pressure with S/T ON kgf/cm2 5.6 5.2 6

Pressure with S/T OFF kPa 490 461 519

Pressure with S/T OFF kgf/cm2 5 4.7 5.3

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Pressure with S/T ON kPa 549 500 598

Pressure with S/T ON kgf/cm2 5.6 5.1 6.1

Pressure with S/T OFF kPa 490 451 529

Pressure with S/T OFF kgf/cm2 5 4.6 5.4

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

0000001101

Pump speed r/min 1000 1000 1000

Timer stroke with S/T ON mm 2 1.5 2.5

Timer stroke with S/T OFF mm 0.8 0.6 1

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 1000 1000 1000

Timer stroke with S/T ON mm 2 1.3 2.7

Timer stroke with S/T OFF mm 0.8 0.4 1.2

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_03

Pump speed r/min 1100 1100 1100

Timer stroke with S/T OFF mm 1.4 0.8 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 5.3 5.2 5.4

MS dimension mm 1.8 1.7 1.9

Control lever angle alpha deg. 10 6 14

Control lever angle beta deg. 20.5 15.5 25.5

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 T=6~9Nm(0.6~0.9kgfm)

Information:

3. Remove elbow (1) and fan drive lubricant tube (2).4. Loosen the clamps on hose (7), and move the hose down from cover (5).5. Disconnect cab heater return hose (6) at the valve.6. Mark the location of coolant conditioner hoses (3) and (4), and disconnect them at the fittings. 7. Remove O-ring seal (13) from elbow (11).8. Remove elbow (11) and tube (9).9. Disconnect cab heater supply valve (10) at the fitting.10. Remove four bolts (12) that hold the water pump to the bonnet. Remove O-ring seal (8) from the water pump. 11. Remove four nuts (15) and one bolt that hold water pump (14) to the timing gear housing.12. Remove the water pump and O-ring seal. The following steps are for installation of the water pump.13. Be sure the mating surface of the water pump and timing gear housing is clean.14. Be sure the mating surface of the water pump and bonnet is clean.15. Install a new O-ring seal on water pump (14).16. Install a new gasket between the water pump and the bonnet while installing the water pump on the timing gear housing.17. Install the four nuts and one bolt that hold water pump (14) to the timing gear housing.18. Install four bolts (12) that hold the water pump to the bonnet.19. Connect cab heater supply valve (10) to the fitting.20. Put clean glycerin on the O-ring seals, and install elbow (11) and tube (9). Install a new O-ring seal (13) in the elbow.21. Connect the coolant condition hoses (3) and (4) to the fittings. Connect the hoses in their original location.22. Connect cab heater return hose (6) to the valve.23. Move hose (7) into position on cover (5), and tighten the hose clamps.24. Install elbow (1) with new gaskets, and install fan drive lubricant tube (2).25. Fill the cooling system with coolant to the correct level. See the Maintenance Guide.Disassemble Water Pump
Start By:a. remove water pump 1. Remove O-ring seal (1) from adapter (2).2. Remove adapter (2) with a screwdriver. Remove the seal from the edge of adapter (2).3. Remove bolt (3) and the washer. 4. Remove impeller (4) from the water pump housing with Tooling (A). 5. Remove seal assembly (5). Remove ring and seal (6). 6. Remove the bolt and washer that hold gear (7) on the water pump shaft.7. Remove gear (7) with Tooling (B).8. Remove bolts and retainer (9).9. Remove O-ring seal (8). 10. Remove shaft (10) and the bearings as a unit.11. Remove bearing (11), spacer (12) and bearing (13) from shaft (10).12. Remove the lip-type seal from the gear side of the water pump. Remove the ring and seal from the impeller side of the water pump.13. Use 6V-1541 Quick Cure Primer to clean shaft (10) and the seal counterbore