104769-2161 ZEXEL 9 460 610 368 BOSCH INJECTION-PUMP ASSEMBLY 9460610368 1047692161

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Information injection-pump assembly

BOSCH 9 460 610 368 9460610368

ZEXEL 104769-2161 1047692161

Cross reference number

BOSCH 9 460 610 368 9460610368

ZEXEL 104769-2161 1047692161

Zexel num

Bosch num

Firm num

Name

104769-2161

9 460 610 368

INJECTION-PUMP ASSEMBLY

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 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 31.7 31.3 32.1

Difference in delivery mm3/st. 2

Basic *

Remarks
Full

Injection timing adjustment_02

Pump speed r/min 900 900 900

Boost pressure kPa 33.35 32 34.7

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 39 38.6 39.4

Difference in delivery mm3/st. 2

Basic *

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 2500 2500 2500

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 19 14 24

Injection timing adjustment_04

Pump speed r/min 2350 2350 2350

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 36.3 34.8 37.8

Injection timing adjustment_05

Pump speed r/min 2300 2300 2300

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 41.3 37.8 44.8

Injection timing adjustment_06

Pump speed r/min 2200 2200 2200

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 43.5 40.5 46.5

Injection timing adjustment_07

Pump speed r/min 1800 1800 1800

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 43.2 41.2 45.2

Injection timing adjustment_08

Pump speed r/min 1200 1200 1200

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 44 42 46

Injection timing adjustment_09

Pump speed r/min 900 900 900

Boost pressure kPa 33.35 32 34.7

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 39 38.1 39.9

Remarks
Full

Injection timing adjustment_10

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 31.7 30.8 32.6

Remarks
CBS

Injection quantity adjustment

Pump speed r/min 2350 2350 2350

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 36.3 35.3 37.3

Difference in delivery mm3/st. 4.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 3

Governor adjustment

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 7.6 6.6 8.6

Difference in delivery mm3/st. 0.9

Basic *

Governor adjustment_02

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 7.6 6.6 8.6

Governor adjustment_03

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

Boost compensator adjustment

Pump speed r/min 900 900 900

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 9.6 6.6 12.6

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. 38 38

Basic *

Speed control lever angle

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

Speed control lever angle_02

Pump speed r/min 900 900 900

Boost pressure kPa 46.95 45.6 48.3

Boost pressure mmHg 352 342 362

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 900 900 900

Boost pressure kPa 46.8 45.6 48

Boost pressure mmHg 352 342 362

Overflow quantity cm3/min 390 258 522

Stop lever angle

Pump speed r/min 900 900 900

Boost pressure kPa 46.95 45.6 48.3

Boost pressure mmHg 352 342 362

Pressure kPa 372.5 343 402

Pressure kgf/cm2 3.8 3.5 4.1

Basic *

Stop lever angle_02

Pump speed r/min 900 900 900

Boost pressure kPa 46.95 45.6 48.3

Boost pressure mmHg 352 342 362

Pressure kPa 372.5 343 402

Pressure kgf/cm2 3.8 3.5 4.1

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Boost pressure kPa 46.95 45.6 48.3

Boost pressure mmHg 352 342 362

Pressure kPa 578.5 549 608

Pressure kgf/cm2 5.9 5.6 6.2

Stop lever angle_04

Pump speed r/min 2300 2300 2300

Boost pressure kPa 46.95 45.6 48.3

Boost pressure mmHg 352 342 362

Pressure kPa 706 677 735

Pressure kgf/cm2 7.2 6.9 7.5

0000001101

Pump speed r/min 900 900 900

Boost pressure kPa 46.95 45.6 48.3

Boost pressure mmHg 352 342 362

Timer stroke mm 1.3 1.1 1.5

Basic *

_02

Pump speed r/min 900 900 900

Boost pressure kPa 46.95 45.6 48.3

Boost pressure mmHg 352 342 362

Timer stroke mm 1.3 1.1 1.5

_03

Pump speed r/min 1800 1800 1800

Boost pressure kPa 46.95 45.6 48.3

Boost pressure mmHg 352 342 362

Timer stroke mm 4.85 4.3 5.4

_04

Pump speed r/min 2300 2300 2300

Boost pressure kPa 46.95 45.6 48.3

Boost pressure mmHg 352 342 362

Timer stroke mm 6.85 6.3 7.4

_05

Pump speed r/min 2500 2500 2500

Boost pressure kPa 46.95 45.6 48.3

Boost pressure mmHg 352 342 362

Timer stroke mm 6.95 6.5 7.4

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 6.64 6.54 6.74

MS dimension mm 1.8 1.7 1.9

BCS stroke mm 3.9 3.8 4

Control lever angle alpha deg. 23 19 27

Control lever angle beta deg. 42 37 47

Control lever angle gamma deg. 11 10.5 11.5

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Adjusting method (dummy bolt method): 1. Adjust at boost pressure P = P1 {P2}. 2. Position the control lever at the adjusting point in the table, hold the dummy bolt against the lever and then fix. 3. Install the potentiometer so that the output voltage is V3 (applied voltage Vi) at the fixed point. 4. After completing potentiometer installation, remove the dummy bolt. In the following condition, change the installation position of the potentiometer to adjust the output voltage to within the specified values. Measure the injection quantity at control lever position a (shim thickness = approximately L mm) at N = N1 r/min, determine the voltage using the formula, and adjust the potentiometer. A:Adjustment conditions B:Adjustment value C:Position of the control lever N:Pump speed Q:Injection quantity Vo:Output voltage E:Conversion formula F:Adjusting point G:Idle H:Full speed K:Applied voltage X:Injection quantity (cm3/1,000st) Y:Voltage (V)
----------
P1=0kPa P2=0mmHg V3=4.32+-0.03V Vi=10V N1=1200r/min a=15.5deg L=8.4mm
----------
N1=1,200r/min V3=4.32+-0.03V Q1=14+-1cm3/1,000st V1=measure V2=measure K=10V J=V+-0.05=0.1115Q+2.7557

0000001901 M-CSD ADJUSTMENT

M-CSD adjustment 1. Move the lever E clockwise and when it contacts the stopper D, adjust screw B so that the timer piston advance is a (L1). Then, fix using the nut. 2. With intermediate lever screw (C)'s fixing lever (E) positioned as in 1., pull the intermediate lever in direction X. After confirming that it contacts the stop position, adjust so that screw (C) contacts lever (E) and then fix using the nut. (In condition (2), intermediate lever: full speed position, at timer advance a.) Confirm that the timer piston advances to b deg when the intermediate lever is returned. 3. Fast idle adjustment Pull the intermediate lever in direction x to contact the stopper and adjust the screw (A) so that the gap between the idle set bracket and the idle screw is L2. Fix using the nut. The gap between the control lever at the idle position and the screw (A) must be L3. (F) Control lever (G) Intermediate lever
----------
a=2deg b=0deg L1=1.6mm L2=6+-0.5mm L3=(1.7)mm
----------
T1=6~9N-m(0.6~0.9kgf-m) T2=5~7N-m(0.5~0.7kgf-m) L2=6+-0.5mm

0000002001 DASHPOT ADJUSTMENT

Adjustment of the dash pot 1. Insert a block gauge L (thickness gauge) between the idle set bracket and the idle screw. 2. In the above condition, adjust so that the dashpot adjusting screw (A) contacts the pushrod. Then, fix using the nut. Record the dashpot return time t. a = alpha
----------
L=3.8+-0.05mm t=1.8+-0.5sec
----------
T=6.0~7.0Nm{0.6~0.7kgfm} b=7.4deg L=3.8+-0.05mm