104749-3030 ZEXEL 9 460 610 217 BOSCH INJECTION-PUMP ASSEMBLY 9460610217 1047493030 md077260

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 460 610 217 9460610217

ZEXEL 104749-3030 1047493030

MITSUBISHI MD077260 md077260

Cross reference number

BOSCH 9 460 610 217 9460610217

ZEXEL 104749-3030 1047493030

MITSUBISHI MD077260 md077260

Zexel num

Bosch num

Firm num

Name

104749-3030
104749-3031

9 460 610 217

MD077260 MITSUBISHI

INJECTION-PUMP ASSEMBLY
4D65 *

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 1250 1250 1250

Boost pressure kPa 78.65 77.3 80

Boost pressure mmHg 590 580 600

Average injection quantity mm3/st. 46.8 46.3 47.3

Difference in delivery mm3/st. 3

Basic *

Injection timing adjustment_02

Pump speed r/min 750 750 750

Boost pressure kPa 33.35 32 34.7

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 40.7 40.2 41.2

Difference in delivery mm3/st. 3.5

Basic *

Injection timing adjustment_03

Pump speed r/min 2750 2750 2750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 6.5 1.5 11.5

Injection timing adjustment_04

Pump speed r/min 2250 2250 2250

Boost pressure kPa 78.65 77.3 80

Boost pressure mmHg 590 580 600

Average injection quantity mm3/st. 40.7 38.2 43.2

Injection timing adjustment_05

Pump speed r/min 1250 1250 1250

Boost pressure kPa 78.65 77.3 80

Boost pressure mmHg 590 580 600

Average injection quantity mm3/st. 46.8 45.8 47.8

Injection timing adjustment_06

Pump speed r/min 750 750 750

Boost pressure kPa 33.35 32 34.7

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 40.7 39.7 41.7

Injection timing adjustment_07

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 35.2 32.7 37.7

Injection quantity adjustment

Pump speed r/min 2750 2750 2750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 6.5 3.5 9.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 3000 3000 3000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

Governor adjustment

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 6.5 5 8

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 2

Governor adjustment_03

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 6.5 4.5 8.5

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. 53 43 63

Basic *

Speed control lever angle

Pump speed r/min 400 400 400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 420 288 552

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 78.65 77.3 80

Boost pressure mmHg 590 580 600

Pressure kPa 470.5 441 500

Pressure kgf/cm2 4.8 4.5 5.1

Basic *

Stop lever angle_02

Pump speed r/min 600 600 600

Boost pressure kPa 78.65 77.3 80

Boost pressure mmHg 590 580 600

Pressure kPa 313.5 284 343

Pressure kgf/cm2 3.2 2.9 3.5

Stop lever angle_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 78.65 77.3 80

Boost pressure mmHg 590 580 600

Pressure kPa 470.5 441 500

Pressure kgf/cm2 4.8 4.5 5.1

Stop lever angle_04

Pump speed r/min 2250 2250 2250

Boost pressure kPa 78.65 77.3 80

Boost pressure mmHg 590 580 600

Pressure kPa 696.5 667 726

Pressure kgf/cm2 7.1 6.8 7.4

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 78.65 77.3 80

Boost pressure mmHg 590 580 600

Timer stroke mm 4.1 3.9 4.3

Basic *

_02

Pump speed r/min 600 600 600

Boost pressure kPa 78.65 77.3 80

Boost pressure mmHg 590 580 600

Timer stroke mm 1.3 0.7 1.9

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 78.65 77.3 80

Boost pressure mmHg 590 580 600

Timer stroke mm 4.1 3.7 4.5

_04

Pump speed r/min 2250 2250 2250

Boost pressure kPa 78.65 77.3 80

Boost pressure mmHg 590 580 600

Timer stroke mm 8.2 7.8 8.6

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 33.2 32.2 34.2

Timer stroke variation dT mm 0.6 0.4 0.8

Basic *

_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 33.2 32.2 34.2

Timer stroke TA mm 3.5 3.5 3.5

Timer stroke variation dT mm 0.6 0.2 1

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 25.2 24.2 26.2

Timer stroke TA mm 2.9 2.3 3.5

Timer stroke variation dT mm 1.2 1.2 1.2

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 1 0.9 1.1

BCS stroke mm 3.6 3.5 3.7

Control lever angle alpha deg. 59 55 63

Control lever angle beta deg. 41 38 44

Test data Ex:

0000001801 DASHPOT ADJUSTMENT

Adjustment of the dash pot Adjust the lever position so that the lever and the dashpot contact at a deg (L mm) from the idle lever position. A = dashpot b = dashpot contact point
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a=8+-2deg L=5.2+-1mm
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L=4.2~6.2mm

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD Adjust for the ambient temperature at adjustment in accordance with the graph. (1)Timer stroke: adjust according to graph. (2)Fast idle (D): insert a block gauge L1 between the control lever (A) and the idle adjusting screw. Adjust screw (C) so that clearance between the control lever (A) and the fast idle lever's pin (B) is L2 as determined from the graph. Y1 = timer stroke Y2 = control lever position X = temperature Y1 = timer stroke Y2 = lever position E = lever position (mm) F = lever angle (deg) G = timer stroke (mm)
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L1=5.3+-0.05mm
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L=5.3mm E=Y2=0.152X+4.29(mm) F=Y2=-(mm) G=Y1=-0.035X+2.2(mm)

0000002001 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer In the following condition, change the installation position of the potentiometer to adjust the output voltage to within the specified values. At N (pump speed) = N1 r/min and control lever position a (corresponding to shim thickness L mm), measure the injection quantity, calculate the voltage using the formula and adjust the potentiometer. Vi:Applied voltage C:Position of the control lever N:Pump speed (r/min) V:Output voltage (V) Q:Injection quantity (mm3/st) A:Adjusting point B:Checking point C1:Idle C2:Full speed P1:Boost pressure P2:Boost pressure E:Conversion formula X:Injection quantity Q (cm3/1,000st) Y:Voltage (V)
----------
N1=1000r/min a=19deg L=12.1mm
----------
N1=1000r/min V1=4+-0.03V V2=0.8+-0.7V V3=7.7+-1.2V Q1=22.9cm3/1,000st Vi=10V P1=-kPa P2=-mmHg J=V+-0.03=0.0856Q+2.04

0000002101 BOOST COMPENSATOR ADJUSTMENT

BCS adjustment procedure 1. At pump speed N1 and boost pressure P1 confirm that the BCS moves through its full stroke and then adjust the injection quantity. 2. At pump speed N2 and boost pressure P2, adjust the full load injection quantity using the BCS spring set screw.
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N1=1250r/min N2=750r/min P1=78.6kPa(590mmHg) P2=33.3kPa(250mmHg)
----------