104780-7262 ZEXEL 9 460 613 368 BOSCH INJECTION-PUMP ASSEMBLY 9460613368 1047807262

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 460 613 368 9460613368

ZEXEL 104780-7262 1047807262

Cross reference number

BOSCH 9 460 613 368 9460613368

ZEXEL 104780-7262 1047807262

Zexel num

Bosch num

Firm num

Name

104780-7262
104780-7263

9 460 613 368

INJECTION-PUMP ASSEMBLY
* 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

Checker parts number 407980-2270

ECU part number 407913-1342

ECU power supply D.C. V 12 12 12

TCV drive power supply V 20 20 20

TCV drive power supply D.C. Hz 60 60 60

Wire harness 407980-2300

Intermediate harness 407980-2420

Injection timing adjustment

Pump speed r/min 1050 1050 1050

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 55 54.5 55.5

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 1050 1050 1050

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 59 58.5 59.5

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1050 1050 1050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 64 63.5 64.5

Difference in delivery mm3/st. 3

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 mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 46.6 43.6 49.6

Difference in delivery mm3/st. 3.5

Oil temperature degC 48 46 50

Injection timing adjustment_05

Pump speed r/min 500 500 500

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 56.2 53.2 59.2

Difference in delivery mm3/st. 3.5

Oil temperature degC 48 46 50

Injection timing adjustment_06

Pump speed r/min 700 700 700

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 61.4 58.4 64.4

Difference in delivery mm3/st. 3.5

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1050 1050 1050

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 55 54 56

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_08

Pump speed r/min 1050 1050 1050

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 59 58 60

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_09

Pump speed r/min 1050 1050 1050

Boost pressure kPa 34.7 33.4 36

Boost pressure mmHg 260 250 270

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 61.6 59.6 63.6

Oil temperature degC 50 48 52

Injection timing adjustment_10

Pump speed r/min 1050 1050 1050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 64 63 65

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_11

Pump speed r/min 1400 1400 1400

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 54.2 51.2 57.2

Difference in delivery mm3/st. 3.5

Oil temperature degC 50 48 52

Injection timing adjustment_12

Pump speed r/min 1400 1400 1400

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 64.4 62.4 66.4

Difference in delivery mm3/st. 3.5

Oil temperature degC 50 48 52

Injection timing adjustment_13

Pump speed r/min 1750 1750 1750

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 63.4 60.4 66.4

Difference in delivery mm3/st. 3.5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 1900 1900 1900

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 52.9 50.9 54.9

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 5

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 1900 1900 1900

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 52.9 48.9 56.9

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2050 2050 2050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 24.1 17.6 30.6

Difference in delivery mm3/st. 7

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 13.6 11.6 15.6

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 mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 13.6 11.1 16.1

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

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 75 70 80

Difference in delivery mm3/st. 7

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 mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

Average injection quantity mm3/st. 75 70 80

Difference in delivery mm3/st. 7

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

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 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

TCV duty (%) F TCV 60Hz % 100 100 100

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 1050 1050 1050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Overflow quantity cm3/min 670 540 800

Oil temperature degC 50 48 52

_02

Pump speed r/min 1050 1050 1050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Overflow quantity cm3/min 670 520 820

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1050 1050 1050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 54 54 54

Pressure kPa 628 608 648

Pressure kgf/cm2 6.4 6.2 6.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 500 500 500

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Pressure kPa 549 510 588

Pressure kgf/cm2 5.6 5.2 6

Oil temperature degC 48 46 50

Stop lever angle_03

Pump speed r/min 1050 1050 1050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 54 54 54

Pressure kPa 628 589 667

Pressure kgf/cm2 6.4 6 6.8

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1050 1050 1050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 54 54 54

Timer stroke mm 3 2.8 3.2

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 100 100 100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Timer stroke mm 3.4 1.4 5.4

Oil temperature degC 48 46 50

_03

Pump speed r/min 1050 1050 1050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 54 54 54

Timer stroke mm 3 2.6 3.4

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1750 1750 1750

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 54 54 54

Timer stroke mm 3.3 1.3 5.3

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 100 100 100

Timer stroke mm 9.8 9.2 10.4

Oil temperature degC 50 48 52

_06

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 0 0 0

Timer stroke mm 0 0 0

Oil temperature degC 50 48 52

0000001201

Pump speed r/min 1050 1050 1050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 0 0 0

TPS output voltage V 0.51 0.382 0.638

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1050 1050 1050

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

TCV duty (%) F TCV 60Hz % 0 0 0

TPS output voltage V 0.51 0.382 0.638

Basic *

Oil temperature degC 50 48 52

0000001301

Max. applied voltage V 16 16 16

Test voltage V 25 24 26

0000002701

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.9 5.8 6

MS dimension mm 1.8 1.7 1.9

BCS stroke mm 2.8 2.6 3

Pre-stroke mm 0.2 0.18 0.22

Control lever angle alpha deg. 17 13 21

Control lever angle beta deg. 43 38 48

Test data Ex:

0000001901 POTENTIOMETER ADJUSTMENT

N = pump speed P = boost pressure Q = injection quantity V = potentiometer C = control lever position B = adjusting point D = check point C1 = idle C2 = full speed A = TCV duty 100% Vi = applied voltage input Adjusting method (dummy bolt method): because the potentiometer is a reverse operation type, use caution at adjustment. 1. At pump speed N = N1 and injection quantity Q = Q1, hold the dummy bolt against the control lever and fix using the locknut. At this time move the control lever only from closed to open (idle to full speed). Caution: When it is necessary to return the control lever, first return it once to the idle position and then perform readjustment. 2. When adjusting the potentiometer, position the control lever against the dummy bolt and adjust the potentiometer so that the output voltage is V1. 3. After completing adjustment remove the dummy bolt. Confirm that the potentiometer output voltage is as specified above at the control lever idle position and full position.
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N1=1050(r/min) Q1=43.9+-0.5(mm3/st) V1=4.67+-0.03(V)
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N1=1050(r/min) P1=73.3(kPa) P2=550(mmHg) Q1=43.9+-0.5(mm3/st) V1=4.67+-0.03(V) V2=8.58+-0.93(V) V3=1.42+-0.93(V) Vi=10(V)

0000002001 STOP LEVER ADJUSTMENT

A = adjusting bolt B = locknut C = stop lever Adjusting the stop lever's starting injection quantity At injection quantity adjustment, adjust adjusting bolt A so that the starting injection quantity is as specified. Fix using nut (B) (Tightening torque T).
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L=4.5~10.6(mm) T=3.4~4.9(Nm)(0.35~0.5(kgfm))