104748-0163 ZEXEL 9 460 610 191 BOSCH INJECTION-PUMP ASSEMBLY 9460610191 1047480163


 

Information injection-pump assembly

BOSCH 9 460 610 191 9460610191
ZEXEL 104748-0163 1047480163
104748-0163 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH 9 460 610 191 9460610191
ZEXEL 104748-0163 1047480163


Zexel num
Bosch num
Firm num
Name
104748-0163 
104748-0169 
9 460 610 191 
  MAZDA
INJECTION-PUMP ASSEMBLY
R2 *

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113orSAEJ967d
Test oil temperature degC   45 45 50
Nozzle   105000-2010
Bosch type code   NP-DN12SD12TT
Nozzle holder   105780-2080
Opening pressure MPa   14.7 14.7 15.19
Opening pressure kgf/cm2   150 150 155
Injection pipe
Inside diameter - outside diameter - length (mm)
mm   2-6-840
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   1500 1500 1500
Average injection quantity mm3/st.   38.7 38.2 39.2
Difference in delivery mm3/st.   2.5
Basic   *
Injection timing adjustment_02
Pump speed r/min   2400 2400 2400
Average injection quantity mm3/st.   13.1 10.1 16.1
Injection timing adjustment_03
Pump speed r/min   2125 2125 2125
Average injection quantity mm3/st.   34 32 36
Injection timing adjustment_04
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   38.7 37.7 39.7
Injection timing adjustment_05
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   32.7 30.7 34.7
Injection quantity adjustment
Pump speed r/min   2400 2400 2400
Average injection quantity mm3/st.   13.1 11.1 15.1
Basic   *
Injection quantity adjustment_02
Pump speed r/min   2550 2550 2550
Average injection quantity mm3/st.   4
Governor adjustment
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   8 6 10
Difference in delivery mm3/st.   2
Basic   *
Governor adjustment_02
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   8 6 10
Timer adjustment
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   42 42
Basic   *
Speed control lever angle
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   0 0 0
Remarks
Magnet OFF
 
0000000901
Pump speed r/min   1250 1250 1250
Overflow quantity cm3/min   430 298 562
Stop lever angle
Pump speed r/min   1250 1250 1250
Pressure kPa   510 481 539
Pressure kgf/cm2   5.2 4.9 5.5
Basic   *
Stop lever angle_02
Pump speed r/min   500 500 500
Pressure kPa   294.5 265 324
Pressure kgf/cm2   3 2.7 3.3
Stop lever angle_03
Pump speed r/min   1250 1250 1250
Pressure kPa   510 481 539
Pressure kgf/cm2   5.2 4.9 5.5
Stop lever angle_04
Pump speed r/min   1500 1500 1500
Pressure kPa   578.5 549 608
Pressure kgf/cm2   5.9 5.6 6.2
Stop lever angle_05
Pump speed r/min   2125 2125 2125
Pressure kPa   745.5 716 775
Pressure kgf/cm2   7.6 7.3 7.9
0000001101
Pump speed r/min   1250 1250 1250
Timer stroke mm   3.5 3.3 3.7
Basic   *
_02
Pump speed r/min   1250 1250 1250
Timer stroke mm   3.5 3.2 3.8
_03
Pump speed r/min   1500 1500 1500
Timer stroke mm   4.7 4.1 5.3
_04
Pump speed r/min   2125 2125 2125
Timer stroke mm   7.6 7 8.2
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.   28.2 27.2 29.2
Timer stroke TA mm   2.7 2.5 2.9
Basic   *
_02
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   28.2 26.7 29.7
Timer stroke TA mm   2.7 2.4 3
_03
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   18.1 16.6 19.6
Timer stroke TA mm   1.5 0.8 2.2
Timing setting
K dimension mm   3.3 3.2 3.4
KF dimension mm   5.8 5.7 5.9
MS dimension mm   1.5 1.4 1.6
Control lever angle alpha deg.   30 28 32
Control lever angle beta deg.   45 40 50

Test data Ex:

0000001801 M-CSD ADJUSTMENT

Test data 104748-0163
M-CSD adjustment 1. Fixing the M-CSD (1)At roller holder advance angle a adjust the lever shaft ball pin so that it contacts the roller holder. (2)At this time, adjust the position of the M-CSD lever (A) using adjusting screw (C) so that the clearance between the M-CSD lever (A) and the stopper (B) becomes L1. Then fix using nut (D). TT 2. M-FICD adjustment (1)Move the CSD lever (A) through its full stroke. (2)Adjust screw (E) so that the control lever (G)'s position is b (the clearance between the control lever and the idling set screw is L2). Then fix using the nut (F). TT Pump speed NE H = from idle to position b
----------
L1=0.5+2mm L2=4.8+-1mm a=0deg b=7deg T=6~9N-m(0.6~0.9kgf-m)
----------
L1=0.5+2mm L2=4.8+-1mm T=6~9N-m(0.6~0.9kgf-m) b=7deg

0000001901 MICROSWITCH ADJUSTMENT

Test data 104748-0163
Microswitch adjustment 1. Set the control lever position at a (distance from the idling setscrew is L1). 2. Adjust the lever screw so that the microswitch turns ON and fix using the nut. Adjustment of the V-FICD 1. V-FICD installation position adjustment (1)Maintain the control lever position b. (2)Adjust the position of the bracket so that the clearance between the control lever's roller and the actuator's hook at initial installation is L2. Then, fix using the nut. 2. V-FICD stroke adjustment (1)Move the actuator through its full stroke. (2)Adjust the adjusting screw so that the control lever clearance is c (the clearance between the control lever and the idling set screw is L3), then fix using the nut. (3)Confirm full stroke at P1 {P2}. A = from idle B = adjusting screw C = gap at installation D = microswitch
----------
a=12.5deg b=0deg c=5deg L1=8.5+-1mm L2=2+2-1mm L3=3.4+-1mm
----------
a=12.5deg c=5deg L1=8.5+-1mm L2=2+2-1mm L3=3.4+-1mm

0000002001 FICD BRACKET&CONTROL LEVER

Test data 104748-0163
FICD bracket and control lever assembly L = ensure at least L
----------

----------
L=3 or more mm




Information:

Air Cleaner Indicator
This engine is equipped with an air cleaner mounted service indicator. A colored piston showing in the window indicates the need for servicing the air cleaner. Observe the air cleaner service indicator at regular scheduled intervals. Clean or replace the air cleaner element when the yellow diaphragm enters the red zone or the red piston locks in the visible position.If your air cleaner element becomes plugged, the air can split the element filter material. Unfiltered air will drastically accelerate internal engine wear. Excessive exhaust smoke and/or loss of power may indicate a need for air cleaner element inspection. Perform maintenance on the air cleaner as instructed in this topic.Keep spare filter elements on hand for replacement. The element should be thoroughly checked for rips or tears in the filter material, seal/gasket damage and replaced at least every year or 250 hours.Test Service Indicator
Air cleaner indicators are inexpensive but important instruments which function to show air filter element restriction as the element is progressively filled (plugged) with dust. In average dust conditions, the air cleaner indicators should be tested for proper operation Every 250 Hours . If dust is severe, the indicator should be checked Daily. To test the indicator, perform the following checks.* Check for ease of resetting; should reset in less than a maximum of three pushes.* Check the movement of the yellow core when the engine is accelerated to rated engine speed. The yellow core should latch at or very close to the highest vacuum obtained.If the indicator will NOT reset easily, or the yellow core will not latch at highest vacuum, the indicator(s) should be replaced. If the new indicator will not reset, the indicator sensor hole may be plugged.THE INDICATOR SHOULD BE REPLACED AT OVERHAUL AND/OR MAJOR ENGINE COMPONENT REPLACEMENT. THE INDICATOR MUST BE REPLACED EVERY YEAR REGARDLESS OF OPERATING CONDITIONS. When installing a new indicator, excessive tightening force may crack the top of the indicator. Tighten the indicator to a torque value of 2 N m (18 lb in). Contact your Caterpillar dealer for parts and/or assistance. Clean/Replace Air Cleaner Elements
Never service the air cleaner with the engine running since this will allow dirt to enter the engine. Check the inlet piping for leaks. Make all repairs to inlet piping immediately, as dirt and debris could enter the engine causing damage to the turbocharger and engine components.Clean or replace elements using these recommendations and/or your weather and operating conditions, or when required by the restriction indicator.
1. Remove air cleaner cover and element. Clean or discard used element. Refer to SEBF8062, Guideline for Reusable Parts-Cleaning and Inspection of Air Filters. 2. Cover air inlet opening with a clean cloth or towel to prevent dirt and debris from entering the engine. 3. Clean the inside of the air cleaner cover and body. 4. Remove cloth from air inlet opening and install clean element while noting arrows indicating air flow on the side of the element. 5. Install cover and reset service indicator.Cleaning

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