104745-0030 ZEXEL 9 460 613 413 BOSCH INJECTION-PUMP ASSEMBLY 9460613413 1047450030

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 613 413 9460613413

ZEXEL 104745-0030 1047450030

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Cross reference number

BOSCH 9 460 613 413 9460613413

ZEXEL 104745-0030 1047450030

Zexel num

Bosch num

Firm num

Name

104745-0030
104745-0031

9 460 613 413

INJECTION-PUMP ASSEMBLY
* 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)
Left L

(Solenoid timer adjustment condition)
With S/T O-ring; S/T ON. ON

Injection timing adjustment

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 48.7 48.2 49.2

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. 44.8 41.8 47.8

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 48.7 47.7 49.7

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 44.3 40.8 47.8

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2450 2450 2450

Average injection quantity mm3/st. 15.7 12.7 18.7

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 8

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2450 2450 2450

Average injection quantity mm3/st. 15.7 5.7 25.7

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 9 8 10

Difference in delivery mm3/st. 1.7

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 9 7.5 10.5

Difference in delivery mm3/st. 2.2

Basic *

Oil temperature degC 48 46 50

Boost compensator adjustment

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 17 15 19

Difference in delivery mm3/st. 3

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 70 55 90

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 70 50 90

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 360 360 360

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 1250 1250 1250

Overflow quantity with S/T ON cm3/min 420 290 550

Overflow quantity with S/T OFF cm3/min 460 330 590

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Pressure with S/T ON kPa 569 530 608

Pressure with S/T ON kgf/cm2 5.8 5.4 6.2

Pressure with S/T OFF kPa 471 442 500

Pressure with S/T OFF kgf/cm2 4.8 4.5 5.1

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Pressure with S/T OFF kPa 471 432 510

Pressure with S/T OFF kgf/cm2 4.8 4.4 5.2

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke with S/T ON mm 5.7 5.3 6.1

Timer stroke with S/T OFF mm 4.1 3.9 4.3

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 500 500 500

Timer stroke with S/T ON mm 1.8 0.8 2.8

Oil temperature degC 48 46 50

_03

Pump speed r/min 1250 1250 1250

Timer stroke with S/T ON mm 5.7 5.1 6.3

Timer stroke with S/T OFF mm 4.1 3.7 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_04

Pump speed r/min 2000 2000 2000

Timer stroke with S/T ON mm 9.2 8.2 10

Timer stroke with S/T OFF mm 7.6 7 8.2

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 35.6 35.1 36.1

Timer stroke TA mm 3.8 3.8 3.8

Timer stroke variation dT mm 0.3 0.1 0.5

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 35.6 34.6 36.6

Timer stroke variation dT mm 0.3 -0.1 0.7

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 22.1 20.6 23.6

Timer stroke variation dT mm 1 0.5 1.5

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 6.01 5.91 6.11

MS dimension mm 0.9 0.8 1

Pre-stroke mm 0.03 0.01 0.05

Control lever angle alpha deg. 12.5 8.5 16.5

Control lever angle beta deg. 40 37 43

Test data Ex:

0000001801 CONTROL STANDARD AT IDLING

Standards for idle difference in delivery control After idle adjustment, measure the idle injection quantities of (A) to (D). Install the colored rings to the delivery valve holders (A) to (D) in accordance with the table. (A): A cylinder (B) :B cylinder (C) : C cylinder (D): D cylinder (E): Collar ring (F): (A) >= (C) (G): (C) > (A) (H): (A) - (C) or (C) - (A) (I): 0.2, 0.1(mm3/st) (J): (B) - (D) or (D) - (B) (K): Ring color (L): At least 0.6 mm3/st (M): 0.3, 0.4, 0.5 (mm3/st) (N): 0.2, 0.1, 0.0 (mm3/st) (O): (B) >= (D) (P): (D) > (B) (T): Yellow (U): White (V): Red
----------

----------

0000001901 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Dummy bolt method 1. Hold the dummy bolt against the control lever at position Np = N1 (r/min) and Q = Q1 (mm3/st) and fix using the lock nut. 2. When adjusting the potentiometer, position the control lever against the dummy bolt and adjust so that the output voltage is V1 (V). 3. After adjustment, remove the dummy bolt and confirm that the potentiometer output voltage at the control lever's idling and full speed positions is as specified above. Vi:Applied voltage N:Pump speed (r/min) V:Output voltage (V) Q:Injection quantity (mm3/st) A:Adjusting point B:Checking point C:Position of the control lever C1:Idling C2:Full speed P1:Boost pressure (kPa) P2:Boost pressure (mmHg)
----------
N1=1500(r/min) Q1=15.2+-1.0(mm3/st) V1=4.97+-0.03(V)
----------
N1=1500(r/min) Q1=15.2+-1.0(mm3/st) V1=4.97+-0.03(V) V2=1.73+-0.70(V) V3=8.40+-0.53(V) Vi=10(V) P1=0(kPa) P2=0(mmHg) a=18.0(deg) b=0(deg) c=40.0+-3.0(deg)

0000002001 WIRE

(1)Wire length confirmation Accelerator wire (idle~full stroke: L1 mm) (2)Adjustment of the two stage actuator 1. Apply negative pressure P1 (kPa) {P2 (mmHg)} to the actuator through the negative pressure suction inlet (A). 2. In the above condition, adjust using screw (C) so that the control lever (B) position is a [clearance L2+-0.5 (mm) from the idle screw (E)] , and fix using the nut (D). (Tightening torque T) b:Angle alpha
----------
L1=34.1+-3.5(mm) L2=4.6(mm) P1=-66.6(kPa) P2=-500(mmHg) a=7.6(deg) b=12.5+-4(deg) T=6~9(Nm)(0.6~0.9(kgfm))
----------
a=7.6(deg) b=12.5+-4(deg) L2=(4.6(mm))

Information:

ACTION REQUIRED
Replace cylinder head, reusing cylinder head bolts and washers after performing visual inspection. Reinstall injector, injector return line, and quill tube with new injector seals, injector return line seals, and quill tube bolts. Reference KENR6052 for removal and installation procedures and for troubleshooting guidance on diagnosing a leaking injector sleeve refer to the info below.
If the source of the sodium cannot be isolated via other normal testing of individual components (water pumps, oil coolers, etc.) then complete the following procedure:
1. Shut down the engine and allow system to cool.
2. Flip the ground level shutdown switch on the truck front bumper and leave the switch engaged. This action disables the fuel injection.
3. Verify that the engine will crank but the engine does NOT start.
4. Pull the last exhaust manifold from each bank of the engine.
5. Pressurize the truck cooling system, refer to Testing and Adjusting, KENR5397 for additional information.
6. Hold pressure on the cooling system for no more than 10 minutes for the first test. If the leak is bad, holding the pressure too long could risk hydraulic lock.
7. While cranking the engine, shine a light up into the exhaust manifolds and look for cylinders that are puffing steam and white smoke. Refer to Image 1.
8. Verify any leaks by pulling the exhaust thermocouple port from the exhaust runner on that cylinder. Check for signs of moisture/steaming in that exhaust runner.
9. Repair any leaking injector sleeve by replacing the head.
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-9000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
9001-18000 hrs,
25-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 8.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
The 8 hour labor allowance consists of:
4 hours troubleshooting max per repair
4 hours repair time
If more than one cylinder has failed, an additional 4 hours repair time per additional cylinder is allowed. Repairing up to 4 cylinders (793F) and 6 cylinders (797B, 797F) in chassis is allowed. No additional troubleshooting time is allowed.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.