104761-3000 ZEXEL 9 460 614 759 BOSCH INJECTION-PUMP ASSEMBLY 9460614759 1047613000

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 759 9460614759

ZEXEL 104761-3000 1047613000

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Cross reference number

BOSCH 9 460 614 759 9460614759

ZEXEL 104761-3000 1047613000

Zexel num

Bosch num

Firm num

Name

104761-3000
104761-3001

9 460 614 759

INJECTION-PUMP ASSEMBLY
* K 11CK VE6 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

Injection timing adjustment

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 48.2 47.7 48.7

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 48.9 43.4 54.4

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 48.2 47.2 49.2

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 48.9 44.9 52.9

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 45.1 40.6 49.6

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 1285 1285 1285

Average injection quantity mm3/st. 8.6 6.6 10.6

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 50 48 52

Injection quantity adjustment_02

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 3

Oil temperature degC 50 48 52

Injection quantity adjustment_03

Pump speed r/min 1285 1285 1285

Average injection quantity mm3/st. 8.6 6.1 11.1

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Governor adjustment

Pump speed r/min 410 410 410

Average injection quantity mm3/st. 9.7 7.7 11.7

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 410 410 410

Average injection quantity mm3/st. 9.7 7.2 12.2

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50 45 55

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50 45 55

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 410 410 410

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 250 250 250

Average injection quantity mm3/st. 5

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 800 800 800

Overflow quantity cm3/min 420 290 550

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 800 800 800

Pressure kPa 549 529 569

Pressure kgf/cm2 5.6 5.4 5.8

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 800 800 800

Timer stroke mm 2.4 2.2 2.6

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 600 600 600

Timer stroke mm 0.9 0.3 1.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 800 800 800

Timer stroke mm 2.4 2 2.8

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 900 900 900

Timer stroke mm 3 2.4 3.6

Oil temperature degC 50 48 52

_05

Pump speed r/min 1150 1150 1150

Timer stroke mm 3.3 2.8 3.7

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 16 16 16

Test voltage V 25 24 26

0000001401

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 12.8 11.8 13.8

Timer stroke TA mm 1.2 0.7 1.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 18 16 20

Timer stroke TA mm 3.3 2.8 3.7

Timer stroke variation dT mm 0 0 0

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 12.7 10.7 14.7

Timer stroke TA mm 1.6 0.4 2.8

Timer stroke variation dT mm 1.7 1.7 1.7

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 6.94 6.84 7.04

MS dimension mm 2.5 2.4 2.6

Pre-stroke mm 0.1 0.08 0.12

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 30 25 35

Test data Ex:

0000001801 STARTING I/Q ADJUSTMENT

Starting Q decrease lever adjustment Adjust using the screw (A) so that the standards are satisfied, then fix using the nut (B) (Torque to T after adjustment) Screw protrusion: L (C) = Cap (D) = Stop lever
----------
L=7.4~11.1mm T=6~9N-m(0.6~0.9kgf-m)
----------
L=7.4~11.1mm T=6~9N-m(0.6~0.9kgf-m) SW=SW10

Information:

Insert the special tool, Piston Ring Inserter to the turbine wheel and install the piston ring.(4) Installation of turbine wheel assembly Install using care not to damage the piston ring. After installation, turn the turbine wheel manually to check that it turns smoothly. If not, disassemble and reassemble again.(5) Installation of compressor wheel (a) Holding the center housing and turbine wheel shaft with fingers, insert slowly into the special tool, Holding Fixture. 1. When inserting, use care not to damage the turbine wheel assembly blades.2. Do not release the shaft before insertion as otherwise the turbine wheel assembly will drop. (b) After tightening the lock nut to specified torque, tighten additionally 110° using special tool, T-handle. Use care not to bend the shaft of turbine wheel assembly.(6) Installation of turbine housing Apply MOLYKOTE to the turbine housing attaching bolt threads and tighten temporarily. Then align match marks and tighten to specified torque. Use care not to damage the turbine wheel assembly blades.(7) Inspection of shaft play [Refer to Item (1) and (2), Section 5.3.1.](8) Installation of compressor housing (a) Lay the compressor housing on the back plate and face the compressor housing downward.(b) Align match marks put at time of disassembly and tighten to specified torque.(9) After assembly, turn the turbine wheel and compressor wheel manually to check that they turn smoothly. If they turn heavily or irregularly, disassemble and check causes.5.4 TD07 Turbocharger
Disassembly
Disassembly Procedure(1) Removal of turbine housing If the turbine housing is hard to remove, tap the turbine housing on its periphery using a plastic hammer or similar tool. The turbine wheel blades are easy to bend. Use care not to damage them.(2) Removal of compressor cover Using a plastic hammer or the similar tool, tap the compressor cover on its periphery and remove. Be careful not to hit the compressor wheel against compressor cover as its blades are easy to bend.(3) Removal of compressor wheel (a) Fit the bearing housing into the turbine housing which is clamped in a vise. (b) Hold the boss on the turbine wheel and remove the lock nut that attaches the compressor wheel. (c) Slowly lift up the compressor wheel to remove it.(4) Removal of insert (a) Remove the snap ring holding the insert into the bearing housing. Retain the snap ring by hand to prevent it from springing out when slipping off the snap ring pliers. (b) Hook the tips of the screwdrivers to the insert at the positions shown in the illustration, then carefully pry up the insert and thrust sleeve as a unit to remove them.Inspection and cleaning
Inspection Procedure(1) Cleaning (a) Immerse disassembled parts in a nonflammable solvent (Daido Kagaku Kogyo's Dai Cleaner T-30 or equivalent) to clean oily contamination. When a commercially-available neutral detergent is used for cleaning, make sure that it does not contain corrosive component. (b) Blow compressed air against the entire internal and external surfaces. (c) Using a plastic scraper or bristle brush, remove deposits from the surfaces. Then, dip parts in the