104700-0510 ZEXEL 9 460 611 530 BOSCH INJECTION-PUMP ASSEMBLY 9460611530 1047000510

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Information injection-pump assembly

BOSCH 9 460 611 530 9460611530

ZEXEL 104700-0510 1047000510

Components :

0.	INJECTION-PUMP ASSEMBLY	104700-0510
1.	_
2.	FUEL INJECTION PUMP	104600-0510
3.	NUMBER PLATE	148636-0800
4.	_
5.	CAPSULE
6.	ADJUSTING DEVICE
7.	NOZZLE AND HOLDER ASSY	105148-1531
8.	Nozzle and Holder	RF1G 13 H50B
9.	Open Pre:MPa(Kqf/cm2)	14.7{150}
10.	NOZZLE-HOLDER	105078-0111
11.	NOZZLE	105007-1370

Scheme ###:

1/6.	[1]	146601-0700	PACKING RING
6.	[1]	146100-0120	SUPPLY PUMP
9.	[1]	148103-0400	COVER
10.	[2]	139104-0000	FLAT-HEAD SCREW
12.	[1]	148200-0920	DRIVE SHAFT
12/3.	[1]	146201-0000	WOODRUFF KEY
17.	[1]	146204-0000	PLAIN WASHER
20.	[1]	148210-0420	ROLLER SET
24.	[1]	146303-0000	BEARING PIN
25.	[1]	146304-0000	BEARING PIN
26.	[1]	146305-0000	CLAMPING BAND
27.	[1]	146205-0000	SLOTTED WASHER
29.	[1]	146220-4820	CAM PLATE
30.	[1]	146600-3000	O-RING
31.	[1]	146300-1900	PUMP PLUNGER
32.	[1]	146301-0200	SLIDING PIECE
33.	[1]	146603-0700	SHIM D17.5&7.5T0.60
34.	[1]	146306-2100	COMPRESSION SPRING
35/1.	[0]	146603-0700	SHIM D17.5&7.5T0.60
35/1.	[0]	146603-0800	SHIM D17.5&7.5T0.70
35/1.	[0]	146603-0900	SHIM D17.5&7.5T0.90
35/1.	[0]	146603-1000	SHIM D17.5&7.5T1.00
35/1.	[0]	146603-1100	SHIM D17.5&7.5T1.20
35/1.	[0]	146603-3600	SHIM D17.5&7.5T2.40
36.	[1]	146600-3000	O-RING
37.	[1]	479765-1320	TIMER PISTON SENSOR
38.	[2]	010206-2040	HEX-SOCKET-HEAD CAP SCREW
39.	[1]	146310-0100	COVER
40.	[2]	146620-5000	BLEEDER SCREW
43.	[1]	146230-0000	SHIM
44.	[1]	146230-0100	PLAIN WASHER
45.	[1]	146231-0001	SLOTTED WASHER
47.	[2]	146233-0000	SLOTTED WASHER
48/1.	[1]	146603-0000	SHIM D17.0&5.2T0.50
48/1.	[1]	146603-0100	SHIM D17.0&5.2T0.80
48/1.	[1]	146603-0200	SHIM D17.0&5.2T1.00
48/1.	[1]	146603-0300	SHIM D17.0&5.2T1.20
48/1.	[1]	146603-0400	SHIM D17.0&5.2T1.50
48/1.	[1]	146603-0500	SHIM D17.0&5.2T1.80
48/1.	[1]	146603-0600	SHIM D17.0&5.2T2.00
48/1.	[1]	146690-1400	SHIM D17&5.2T0.9
48/1.	[1]	146690-1500	SHIM D17&5.2T1.1
48/1.	[1]	146690-1600	SHIM D17&5.2T1.3
48/1.	[1]	146690-1700	SHIM D17&5.2T1.4
48/1.	[1]	146690-1800	SHIM D17&5.2T1.6
48/1.	[1]	146690-1900	SHIM D17&5.2T1.7
48/1.	[1]	146690-5800	SHIM D17&5.2T2.1
48/1.	[1]	146690-5900	SHIM D17&5.2T2.2
48/1.	[1]	146690-6000	SHIM
48/1.	[1]	146690-6100	SHIM D17&5.2T2.4
48/1.	[1]	146690-6200	SHIM D17&5.2T2.5
48/1.	[1]	146690-6300	SHIM D17&5.2T2.6
48/1.	[1]	146690-6400	SHIM D17&5.2T2.7
48/1.	[1]	146690-6500	SHIM
48/1.	[1]	146690-6600	SHIM
48/1.	[1]	146690-6700	SHIM D17&5.2T3.0
48/1.	[1]	146690-6800	SHIM D17&5.2T3.1
48/1.	[1]	146690-6900	SHIM
48/1.	[1]	146690-7000	SHIM
48/1.	[1]	146690-7100	SHIM
48/1.	[1]	146690-7200	SHIM D17&5.2T0.4
48/1.	[1]	146690-7300	SHIM
48/1.	[1]	146690-7400	SHIM
48/1.	[1]	146690-7500	SHIM
48/1.	[1]	146690-7800	SHIM D17&5.2T0.2
49.	[2]	146234-0120	GUIDE PIN
50.	[1]	146403-8220	HYDRAULIC HEAD
50.	[1]	146403-8220	HYDRAULIC HEAD
50.	[1]	146403-8220	HYDRAULIC HEAD
51.	[1]	146600-0000	O-RING
52/1.	[1]	146420-0000	SHIM D9.5&3.0T1.90
52/1.	[1]	146420-0100	SHIM D9.5&3.0T1.92
52/1.	[1]	146420-0200	SHIM D9.5&3.0T1.94
52/1.	[1]	146420-0300	SHIM D9.5&3.0T1.96
52/1.	[1]	146420-0400	SHIM D9.5&3.0T1.98
52/1.	[1]	146420-0500	SHIM D9.5&3.0T2.00
52/1.	[1]	146420-0600	SHIM D9.5&3.0T2.02
52/1.	[1]	146420-0700	SHIM D9.5&3.0T2.04
52/1.	[1]	146420-0800	SHIM D9.5&3.0T2.06
52/1.	[1]	146420-0900	SHIM D9.5&3.0T2.08
52/1.	[1]	146420-1000	SHIM D9.5&3.0T2.10
52/1.	[1]	146420-1100	SHIM D9.5&3.0T2.12
52/1.	[1]	146420-1200	SHIM D9.5&3.0T2.14
52/1.	[1]	146420-1300	SHIM D9.5&3.0T2.16
52/1.	[1]	146420-1400	SHIM D9.5&3.0T2.18
52/1.	[1]	146420-1500	SHIM D9.5&3.0T2.20
52/1.	[1]	146420-1600	SHIM D9.5&3.0T2.22
52/1.	[1]	146420-1700	SHIM D9.5&3.0T2.24
52/1.	[1]	146420-1800	SHIM D9.5&3.0T2.26
52/1.	[1]	146420-1900	SHIM D9.5&3.0T2.28
52/1.	[1]	146420-2000	SHIM D9.5&3.0T2.30
52/1.	[1]	146420-2100	SHIM D9.5&3.0T2.32
52/1.	[1]	146420-2200	SHIM D9.5&3.0T2.34
52/1.	[1]	146420-2300	SHIM D9.5&3.0T2.36
52/1.	[1]	146420-2400	SHIM D9.5&3.0T2.38
52/1.	[1]	146420-2500	SHIM D9.5&3.0T2.40
52/1.	[1]	146420-2600	SHIM D9.5&3.0T2.42
52/1.	[1]	146420-2700	SHIM D9.5&3.0T2.44
52/1.	[1]	146420-2800	SHIM D9.5&3.0T2.46
52/1.	[1]	146420-2900	SHIM D9.5&3.0T2.48
52/1.	[1]	146420-3000	SHIM D9.5&3.0T2.50
52/1.	[1]	146420-3100	SHIM D9.5&3.0T2.52
52/1.	[1]	146420-3200	SHIM D9.5&3.0T2.54
52/1.	[1]	146420-3300	SHIM D9.5&3.0T2.56
52/1.	[1]	146420-3400	SHIM D9.5&3.0T2.58
52/1.	[1]	146420-3500	SHIM D9.5&3.0T2.60
52/1.	[1]	146420-3600	SHIM D9.5&3.0T2.62
52/1.	[1]	146420-3700	SHIM D9.5&3.0T2.64
52/1.	[1]	146420-3800	SHIM D9.5&3.0T2.66
52/1.	[1]	146420-3900	SHIM D9.5&3.0T2.68
52/1.	[1]	146420-4000	SHIM D9.5&3.0T2.70
52/1.	[1]	146420-4100	SHIM D9.5&3.0T2.72
52/1.	[1]	146420-4200	SHIM D9.5&3.0T2.74
52/1.	[1]	146420-4300	SHIM D9.5&3.0T2.76
52/1.	[1]	146420-4400	SHIM D9.5&3.0T2.78
52/1.	[1]	146420-4500	SHIM D9.5&3.0T2.80
52/1.	[1]	146420-4600	SHIM D9.5&3.0T2.82
52/1.	[1]	146420-4700	SHIM D9.5&3.0T2.84
52/1.	[1]	146420-4800	SHIM D9.5&3.0T2.86
52/1.	[1]	146420-4900	SHIM D9.5&3.0T2.88
52/1.	[1]	146420-5000	SHIM D9.5&3.0T2.90
52/1.	[1]	146420-5100	SHIM D9.5&3.0T1.74
52/1.	[1]	146420-5200	SHIM D9.5&3.0T1.76
52/1.	[1]	146420-5300	SHIM D9.5&3.0T1.78
52/1.	[1]	146420-5400	SHIM D9.5&3.0T1.80
52/1.	[1]	146420-5500	SHIM D9.5&3.0T1.82
52/1.	[1]	146420-5600	SHIM D9.5&3.0T1.84
52/1.	[1]	146420-5700	SHIM D9.5&3.0T1.86
52/1.	[1]	146420-5800	SHIM D9.5&3.0T1.88
54.	[4]	146433-0100	GASKET D12&6.4T1.00
55.	[4]	146430-0320	DELIVERY-VALVE ASSEMBLY
56.	[4]	146432-0000	COMPRESSION SPRING
58.	[4]	146440-0220	FITTING
60.	[3]	139106-0100	FLAT-HEAD SCREW
123.	[1]	146620-8800	FLAT-HEAD SCREW
130.	[1]	146421-1020	CAPSULE
130/2.	[1]	139508-0200	GASKET D11.4&8.2T1
130/3.	[1]	146422-0300	BLEEDER SCREW
130/4.	[1]	146600-0500	O-RING
133.	[1]	146600-0600	O-RING
134.	[1]	146600-0700	O-RING
135.	[1]	146110-3220	CONTROL VALVE
135/5.	[1]	146114-0000	SPRING WASHER
136.	[1]	148120-0020	OVER FLOW VALVE
137.	[3]	139512-0500	GASKET
138.	[1]	146669-0920	INLET UNION
158.	[1]	146614-6900	SPACER BUSHING
200.	[1]	146206-0100	COILED SPRING
205.	[1]	029470-4030	WOODRUFF KEY
221.	[1]	148613-2720	BRACKET
235.	[1]	148613-2800	BRACKET
236.	[2]	146620-2700	HEX-SOCKET-HEAD CAP SCREW
236.	[2]	146620-2700	HEX-SOCKET-HEAD CAP SCREW
237.	[1]	146620-0200	HEX-SOCKET-HEAD CAP SCREW
240.	[1]	146688-0920	PULLING ELECTROMAGNET
240/8.	[1]	146600-1700	O-RING
243.	[1]	146621-1000	UNION NUT
245.	[2]	139512-0500	GASKET
246.	[1]	027412-2440	EYE BOLT
247.	[1]	146669-1020	INLET UNION
251.	[1]	020145-1040	BLEEDER SCREW
275.	[1]	148612-1120	BRACKET
276.	[2]	010010-1640	BLEEDER SCREW M10P1.5L16 4T
282.	[1]	139006-4400	BLEEDER SCREW
317.	[1]	139006-5700	BLEEDER SCREW
504/1.	[1]	146649-4500	RESISTER
504/1.	[1]	146649-4600	RESISTER
504/1.	[1]	146649-4700	RESISTER
504/1.	[1]	146649-4800	RESISTER
504/1.	[1]	146649-4900	RESISTER
504/1.	[1]	146649-5000	RESISTER
504/1.	[1]	146649-5100	RESISTER
504/1.	[1]	146649-5200	RESISTER
504/1.	[1]	146649-5300	RESISTER
504/1.	[1]	146649-5400	RESISTER
504/1.	[1]	146649-5500	RESISTER
504/1.	[1]	146649-5600	RESISTER
504/1.	[1]	146649-5700	RESISTER
505.	[1]	148531-2220	GOVERNOR;ELECTRIC
506.	[3]	146620-8900	FLAT-HEAD SCREW
515.	[1]	106144-1070	TIMING CONTROL VALVE
515/8.	[1]	161440-3800	O-RING
515/9.	[1]	161440-3700	O-RING
516.	[2]	010206-1440	HEX-SOCKET-HEAD CAP SCREW M6P1L14
531.	[1]	479765-1020	PULSE GENERATOR
531/6.	[1]	479773-6500	O-RING
800S.	[1]	148009-0620	PUMP HOUSING
800S/1/6.	[1]	146601-0700	PACKING RING
804S.	[1]	146232-0720	COMPRESSION SPRING
810S.	[1]	146600-4620	REPAIR SET
821S.	[1]	146210-5820	ROLLER SET
878S.	[1]	148600-1300	SEAL RING
906.	[1]	148636-0800	NAMEPLATE

Include in #2:

104700-0510 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 460 611 530 9460611530

ZEXEL 104700-0510 1047000510

Zexel num

Bosch num

Firm num

Name

104700-0510
104700-0511

9 460 611 530

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

Governor adjustment

Pump speed r/min 750 750 750

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

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 539.5 510 569

Pump chamber pressure kgf/cm2 5.5 5.2 5.8

Basic *

Governor adjustment_02

Pump speed r/min 100 100 100

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

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 294 294

Pump chamber pressure kgf/cm2 3 3

Governor adjustment_03

Pump speed r/min 750 750 750

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

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 539.5 500 579

Pump chamber pressure kgf/cm2 5.5 5.1 5.9

Governor adjustment_04

Pump speed r/min 2250 2250 2250

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

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 745 696 794

Pump chamber pressure kgf/cm2 7.6 7.1 8.1

Boost compensator adjustment

Pump speed r/min 750 750 750

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

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 7 6.8 7.2

Basic *

Boost compensator adjustment_02

Pump speed r/min 100 100 100

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

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 3.5 1.5 5.5

Boost compensator adjustment_03

Pump speed r/min 360 360 360

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

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 6.9 4.9 8.9

Boost compensator adjustment_04

Pump speed r/min 750 750 750

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

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 7 6.7 7.3

Boost compensator adjustment_05

Pump speed r/min 750 750 750

TCV duty (%) F TCV 60Hz % 70 70 70

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 3.6 1.6 5.6

Boost compensator adjustment_06

Pump speed r/min 2250 2250 2250

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

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 9.85 9.3 10.4

Boost compensator adjustment_07

Pump speed r/min 2250 2250 2250

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

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 0 0 0

Timer adjustment

Pump speed r/min 750 750 750

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

U alpha soll V 2.7 2.7 2.7

Vtps V 0.51 0.382 0.638

Basic *

Timer adjustment_02

Pump speed r/min 750 750 750

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

U alpha soll V 2.7 2.7 2.7

Vtps V 0.51 0.382 0.638

Timer adjustment_03

Pump speed r/min 750 750 750

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

U alpha soll V 2.7 2.7 2.7

Vtps V 1.796 1.591 2.001

Speed control lever angle

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.7 2.7 2.7

Overflow quantity cm3/min 510 380 640

0000000901

Pump speed r/min 1250 1250 1250

U alpha soll + dU alpha soll V 2.49 2.49 2.49

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

Average injection quantity mm3/st. 43.1 42.6 43.6

Difference in delivery mm3/st. 4

Basic *

_02

Pump speed r/min 413 413 413

U alpha soll + dU alpha soll V 1.87 1.87 1.87

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

Average injection quantity mm3/st. 7.4 4.4 10.4

Difference in delivery mm3/st. 1.5

Basic *

Remarks
Confirmation of difference in delivery

_03

Pump speed r/min 2600 2600 2600

U alpha soll + dU alpha soll V 1.82 1.82 1.82

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

Average injection quantity mm3/st. 14 11.5 16.5

Difference in delivery mm3/st. 5

Basic *

Remarks
Confirmation of difference in delivery

_04

Pump speed r/min 100 100 100

U alpha soll + dU alpha soll V 2.76 2.76 2.76

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

Average injection quantity mm3/st. 31.7 21.7 41.7

_05

Pump speed r/min 413 413 413

U alpha soll + dU alpha soll V 1.87 1.87 1.87

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

Average injection quantity mm3/st. 7.4 4.4 10.4

_06

Pump speed r/min 450 450 450

U alpha soll + dU alpha soll V 1.87 1.87 1.87

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

Average injection quantity mm3/st. 10.2 7.2 13.2

_07

Pump speed r/min 500 500 500

U alpha soll + dU alpha soll V 2.47 2.47 2.47

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

Average injection quantity mm3/st. 40.9 38.4 43.4

_08

Pump speed r/min 570 570 570

U alpha soll + dU alpha soll V 1.87 1.87 1.87

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

Average injection quantity mm3/st. 6.1 3.1 9.1

_09

Pump speed r/min 1250 1250 1250

U alpha soll + dU alpha soll V 2 2 2

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

Average injection quantity mm3/st. 19.2 16.7 21.7

_10

Pump speed r/min 1250 1250 1250

U alpha soll + dU alpha soll V 2.49 2.49 2.49

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

Average injection quantity mm3/st. 43.1 42.1 44.1

_11

Pump speed r/min 1500 1500 1500

U alpha soll + dU alpha soll V 2.42 2.42 2.42

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

Average injection quantity mm3/st. 39.8 37.3 42.3

_12

Pump speed r/min 1750 1750 1750

U alpha soll + dU alpha soll V 2.42 2.42 2.42

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

Average injection quantity mm3/st. 41.3 38.8 43.8

_13

Pump speed r/min 2250 2250 2250

U alpha soll + dU alpha soll V 2.43 2.43 2.43

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

Average injection quantity mm3/st. 40.5 38 43

_14

Pump speed r/min 2350 2350 2350

U alpha soll + dU alpha soll V 2.41 2.41 2.41

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

Average injection quantity mm3/st. 39.2 36.7 41.7

_15

Pump speed r/min 2600 2600 2600

U alpha soll + dU alpha soll V 1 1 1

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

Average injection quantity mm3/st. 3

_16

Pump speed r/min 2600 2600 2600

U alpha soll + dU alpha soll V 1.82 1.82 1.82

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

Average injection quantity mm3/st. 14 11.5 16.5

Stop lever angle

Pump speed r/min 413 413 413

U alpha soll + dU alpha soll V 1.87 1.87 1.87

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

Average injection quantity cm3/min 0 0 0

Stop lever angle_02

Pump speed r/min 2350 2350 2350

U alpha soll + dU alpha soll V 2.41 2.41 2.41

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

Average injection quantity cm3/min 0 0 0

0000001101

Pump speed r/min 200 200 200

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

U alpha soll V 2.7 2.7 2.7

Speed output
N=Measure the actual speed. r/min N+-8

0000001201

Pump speed r/min 1250 1250 1250

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

U alpha soll V 2.49 2.49 2.49

Temperature output
Measure T = actual output temperature degC T+-5

0000001301

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

Pre-stroke mm 0.1 0.08 0.12

Test data Ex:

Injection timing adjustment Comp. resistor/voltage

Compensation resistance/compensation voltage comparison A = Compensation resistor number B= Compensation resistance C = Compensation voltage delta U alpha soll
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0000001601 HARNESS & CONNECTOR

Connector and binder assembly specification (1)For A's connector, adjust the position of the protective tube to L1 and install. (2)After assembling the connector and bushing-type clip, fix the FCV harness and the GE cable using the clip B. (3)Route the harness at D from the front to the T.P.S., to the Q adjustment and then to the T.C.V. in that order. (4)At the next step, fix C's P/U connector harness using the clip. A:GE, FCV, TCV and Q adjustment connectors. B:Binder C:Speed pickup connector E:Push type clip F:Q adjustment resistor G:T.P.S. Connector I:Protective tube
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L1=10+-5mm

0000001701 HARNESS & CONNECTOR

P/U Harness position specification Caution: The P/U connector is not fixed to the bracket. (1)With the clip L1 from end of the connector, gather and fix the P/U and TPS harness. (2)After fixing the clip, confirm that the P/U connector can be installed to the bracket installation hole. However, do not fix the connector to the bracket. A:P/U B:P/U Connector C:Binder D:Connector installation bracket hole
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L1=(100mm)

0000001801 HARNESS & CONNECTOR

P/U connector temporary fixing specifications (1)Confirm that the P/U connector can be installed to the bracket's installation hole. (2)Position the P/U connector and harness between the GE cable and the FCV harness and temporarily fix the connector. A:Position between the GE cable and the FCV harness. B:P/U Connector
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