104780-9211 ZEXEL 9 460 614 784 BOSCH INJECTION-PUMP ASSEMBLY 9460614784 1047809211 167003s902

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 784 9460614784

ZEXEL 104780-9211 1047809211

NISSAN-DIESEL 167003S902 167003s902

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Cross reference number

BOSCH 9 460 614 784 9460614784

ZEXEL 104780-9211 1047809211

NISSAN-DIESEL 167003S902 167003s902

Zexel num

Bosch num

Firm num

Name

104780-9211

9 460 614 784

167003S902 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
TD25-TI 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)
Right R

Injection timing adjustment

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 41.5 41 42

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 800 800 800

Boost pressure kPa 37.3 36 38.6

Boost pressure kgf/cm2 0.38 0.366 0.394

Boost pressure mmHg 280 270 290

Average injection quantity mm3/st. 51.8 51.3 52.3

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 63.6 63.1 64.1

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 41.5 40.5 42.5

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 800 800 800

Boost pressure kPa 37.3 36 38.6

Boost pressure kgf/cm2 0.38 0.366 0.394

Boost pressure mmHg 280 270 290

Average injection quantity mm3/st. 51.8 50.8 52.8

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 63.6 62.6 64.6

Difference in delivery mm3/st. 6.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 1200 1200 1200

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 65.3 62.8 67.8

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 1500 1500 1500

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 65.3 62.3 68.3

Oil temperature degC 50 48 52

Injection timing adjustment_09

Pump speed r/min 2000 2000 2000

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 60.7 57.7 63.7

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2500 2500 2500

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 16.7 14.7 18.7

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2750 2750 2750

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2250 2250 2250

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 50.4 50.4 50.4

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2500 2500 2500

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 16.7 13.7 19.7

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 9.4 7.4 11.4

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 9.4 6.9 11.9

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 75 60 95

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 75 60 95

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure kgf/cm2 0 0 0

Boost pressure mmHg 0 0 0

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 1100 1100 1100

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Overflow quantity with S/T ON cm3/min 450 320 580

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1100 1100 1100

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure with S/T ON kPa 510 471 549

Pressure with S/T ON kgf/cm2 5.2 4.8 5.6

Pressure with S/T OFF kPa 432 403 461

Pressure with S/T OFF kgf/cm2 4.4 4.1 4.7

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_02

Pump speed r/min 1100 1100 1100

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 432 393 471

Pressure with S/T OFF kgf/cm2 4.4 4 4.8

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_03

Pump speed r/min 2150 2150 2150

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 647 608 686

Pressure with S/T OFF kgf/cm2 6.6 6.2 7

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1100 1100 1100

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke with S/T ON mm 3.8 3.4 4.2

Timer stroke with S/T OFF mm 2 1.8 2.2

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 700 700 700

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke with S/T OFF mm 0.8

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke with S/T ON mm 3.8 3.3 4.3

Timer stroke with S/T OFF mm 2 1.7 2.3

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_04

Pump speed r/min 2150 2150 2150

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Timer stroke with S/T ON mm 7.8 7.3 8.2

Timer stroke with S/T OFF mm 6.9 6.3 7.5

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1100 1100 1100

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 44 43.5 44.5

Timer stroke TA mm 1.7 1.7 1.7

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 1100 1100 1100

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 44 43 45

Timer stroke TA mm 1.7 1.7 1.7

Timer stroke variation dT mm 0.3 0 0.6

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_03

Pump speed r/min 1100 1100 1100

Boost pressure kPa 80 78.7 81.3

Boost pressure kgf/cm2 0.82 0.806 0.834

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 32 29.5 34.5

Timer stroke TA mm 1.1 1.1 1.1

Timer stroke variation dT mm 0.9 0.5 1.3

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 0.7 0.6 0.8

BCS stroke mm 4.5 4.3 4.7

Pre-stroke mm 0.1 0.08 0.12

Control lever angle alpha deg. 55.5 51.5 59.5

Control lever angle beta deg. 36 31 41

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

A:Adjusting point B:Confirmation point C:Position of the control lever Vi:Applied voltage V:Potentiometer output voltage Q:Injection quantity C1:Idle C2:Full speed
----------

----------
V1=1.4+-0.03V V2=Above9.5V Vi=10V

Information:

General Recommendations and Contamination Control Guidelines for Fuels
Follow all applicable industry standards and all applicable governmental, environmental, and safety guidelines, practices, regulations, and mandates.Note: These general recommendations and guidelines concerning maintenance and care of fuel and fuel storage systems are not intended to be all inclusive. Discuss proper fuel safety and health, handling, and maintenance practices with your fuel supplier. Use of these general recommendations and guidelines does not lessen the engine owners and/or fuel supplier responsibility to follow all industry standard practices for fuel storage and for fuel handling.Note: Where recommendations for draining water and/or sediment and/or debris are stated, dispose of this waste according to all applicable regulations and mandates.Note: Caterpillar filters are designed and built to provide optimal performance and protection of the fuel system components.Clean fuels, as detailed below, are strongly recommended to allow optimal performance and durability of the fuel systems and to reduce power loss, failures, and related down time of engines.Fuels of “ISO 18/16/13” cleanliness levels or cleaner as dispensed into the engine or machine fuel tank should be used. Reduced power, failures and related downtime can result if clean fuels are not used. Fuels of “ISO 18/16/13” are particularly important for new fuel system designs such as Common Rail injection systems and unit injection systems. These new injection system designs utilize higher fuel pressures and are designed with tight clearances between moving parts to meet required stringent emissions regulations. Peak injection pressures in current fuel injection systems may exceed 30,000 psi. Clearances in these systems are less than 5 µm. As a result, particle contaminants as small as 4 µm can cause scoring and scratching of internal pump and injector surfaces and of injector nozzles.Water in the fuel causes cavitation, corrosion of fuel system parts, and provides an environment where microbial growth in the fuel can flourish. Other sources of fuel contamination are soaps, gels, or other compounds that may result from undesirable chemical interactions in the fuels. Gels and other insoluble compounds can also form in biodiesel fuel at low temperatures or if biodiesel is stored for extended periods. An indication of microbial contamination, detrimental fuel additives interactions, or cold temperature gel is very rapid filter plugging of bulk fuel filters or machine fuel filters.To reduce downtime due to contamination, follow these fuel maintenance guidelines in addition to the recommendations given in the "Contamination Control" Chapter in this Special Publication:
Use high-quality fuels per recommended and required specifications (refer to the “Fuel” chapter in this Special Publication).
Do not add new engine oil, waste engine oil or any oil product to the fuel unless the engine is designed and certified to burn diesel engine oil (for example Caterpillar ORS designed for large engines). Engine oils may raise the sulfur level of the fuel and may cause fouling of the fuel system and loss of performance. Engine oils in fuels can also reduce the maintenance intervals of aftertreatment devices in Tier 4 machines.
Use recommended Cat filtration products, including Cat Advanced Efficiency Fuel