104741-3000 ZEXEL 9 460 613 417 BOSCH INJECTION-PUMP ASSEMBLY 9460613417 1047413000 me200099

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 460 613 417 9460613417

ZEXEL 104741-3000 1047413000

MITSUBISHI ME200099 me200099

Cross reference number

BOSCH 9 460 613 417 9460613417

ZEXEL 104741-3000 1047413000

MITSUBISHI ME200099 me200099

Zexel num

Bosch num

Firm num

Name

104741-3000
104741-3001

9 460 613 417

ME200099 MITSUBISHI

INJECTION-PUMP ASSEMBLY
E65X TC * 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

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

Injection timing adjustment

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 53.5 53 54

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 600 600 600

Boost pressure kPa 31.3 30 32.6

Boost pressure mmHg 235 225 245

Average injection quantity mm3/st. 68.2 67.7 68.7

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 75.6 75.1 76.1

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 53.5 52.5 54.5

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 600 600 600

Boost pressure kPa 31.3 30 32.6

Boost pressure mmHg 235 225 245

Average injection quantity mm3/st. 68.2 67.2 69.2

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 75.6 74.6 76.6

Difference in delivery mm3/st. 6.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 71.4 67.4 75.4

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2475 2475 2475

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 33 30 36

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2475 2475 2475

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 33 28 38

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2800 2800 2800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 8

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 365 365 365

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10.5 8.5 12.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 365 365 365

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10.5 8 13

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 mmHg 0 0 0

Average injection quantity mm3/st. 50 40 60

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 50 40 60

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Speed control lever angle

Pump speed r/min 365 365 365

Boost pressure kPa 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 73.3 72 74.6

Boost pressure mmHg 550 540 560

Overflow quantity with S/T ON cm3/min 850 720 980

Overflow quantity with S/T OFF cm3/min 930 800 1060

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T ON kPa 559 520 598

Pressure with S/T ON kgf/cm2 5.7 5.3 6.1

Pressure with S/T OFF kPa 481 461 501

Pressure with S/T OFF kgf/cm2 4.9 4.7 5.1

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 700 700 700

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T ON kPa 422 373 471

Pressure with S/T ON kgf/cm2 4.3 3.8 4.8

Pressure with S/T OFF kPa 284 235 333

Pressure with S/T OFF kgf/cm2 2.9 2.4 3.4

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 800 800 800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T OFF kPa 353 304 402

Pressure with S/T OFF kgf/cm2 3.6 3.1 4.1

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 900 900 900

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T OFF kPa 392 353 431

Pressure with S/T OFF kgf/cm2 4 3.6 4.4

Oil temperature degC 50 48 52

Stop lever angle_05

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T OFF kPa 422 383 461

Pressure with S/T OFF kgf/cm2 4.3 3.9 4.7

Oil temperature degC 50 48 52

Stop lever angle_06

Pump speed r/min 1100 1100 1100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T ON kPa 530 481 579

Pressure with S/T ON kgf/cm2 5.4 4.9 5.9

Pressure with S/T OFF kPa 451 412 490

Pressure with S/T OFF kgf/cm2 4.6 4.2 5

Oil temperature degC 50 48 52

Stop lever angle_07

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T ON kPa 559 510 608

Pressure with S/T ON kgf/cm2 5.7 5.2 6.2

Pressure with S/T OFF kPa 481 452 510

Pressure with S/T OFF kgf/cm2 4.9 4.6 5.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_08

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T ON kPa 696 647 745

Pressure with S/T ON kgf/cm2 7.1 6.6 7.6

Pressure with S/T OFF kPa 628 589 667

Pressure with S/T OFF kgf/cm2 6.4 6 6.8

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T ON mm 6.7 6.2 7.2

Timer stroke with S/T OFF mm 4.7 4.5 4.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 700 700 700

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T ON mm 3.3 2.6 4

Timer stroke with S/T OFF mm 0.8

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T ON mm 6.7 6 7.4

Timer stroke with S/T OFF mm 4.7 4.3 5.1

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T OFF mm 9.8 9.3 10.2

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 3.3 3.2 3.4

KF dimension mm 6.01 5.91 6.11

MS dimension mm 0.7 0.6 0.8

BCS stroke mm 4.5 4.3 4.7

Control lever angle alpha deg. 59 55 63

Control lever angle beta deg. 42 37 47

Test data Ex:

0000001601 BOOST COMPENSATOR ADJUSTMENT

BCS adjustment procedure 1. At full boost pressure, set so that the full injection quantity is within the specifications (adjusting point). 2. Perform boost compensator intermediate operation point adjustment (pump speed N1, boost pressure P1). 3. When injection quantity at boost pressure P2 and pump speed N2 is not as specified, loosen nut (A) and adjust position of screw (B) so that injection quantity is as specified. The screw position should be within +-1 turn of initial position. 4. The nut tightening torque is T.
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N1=600r/min N2=550r/min P1=31.3kPa(235mmHg) P2=0kPa(0mmHg) T=6~9N-m(0.6~0.9kgf-m)
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SW=10mm T=6~9N-m(0.6~0.9kgf-m)

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Vi:Applied voltage C:Position of the control lever N:Pump speed V:Output voltage Q:Injection quantity A:Adjusting point C1:Idling C2:Full speed
----------

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V1=1.6+-0.03V V2=(8.6V) Vi=10V

0000001901 W-FICD LEVER ADJUSTMENT

W-FICD adjustment (1)Insert a block gauge L1 determined from the graph between the control lever (B) and the idling set screw (A). (2)Fix bolt (E) in the position where W-FICD lever (C) contacts the control lever (D). (Tighten to torque T.) (3)Remove the block gauge and shims after completing adjustment. Caution: The temperature of the wax at adjustment must not exceed a. Y = control lever dimension L (control lever position) X = temperature t (deg C)
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L1=L+-0.3mm T=3.4~4.9N-m(0.35~0.5kgf-m) a=35degC
----------