104700-3000 ZEXEL 9 460 614 814 BOSCH INJECTION-PUMP ASSEMBLY 9460614814 1047003000

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 460 614 814 9460614814

ZEXEL 104700-3000 1047003000

Cross reference number

BOSCH 9 460 614 814 9460614814

ZEXEL 104700-3000 1047003000

Zexel num

Bosch num

Firm num

Name

104700-3000
104700-3001

9 460 614 814

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

Manual controller assembly 105782-8280

Manual controller 105782-8270

Wire harness 407980-2390

Intermediate harness 407980-2400

Governor adjustment

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.86 2.86 2.86

Pump chamber pressure kPa 588.5 559 618

Pump chamber pressure kgf/cm2 6 5.7 6.3

Basic *

Governor adjustment_02

Pump speed r/min 100 100 100

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

U alpha soll V 2.86 2.86 2.86

Pump chamber pressure kPa 294 294

Pump chamber pressure kgf/cm2 3 3

Governor adjustment_03

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.86 2.86 2.86

Pump chamber pressure kPa 588 549 627

Pump chamber pressure kgf/cm2 6 5.6 6.4

Governor adjustment_04

Pump speed r/min 2100 2100 2100

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

U alpha soll V 2.86 2.86 2.86

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 1000 1000 1000

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

U alpha soll V 2.86 2.86 2.86

Timer stroke mm 9.9 9.7 10.1

Basic *

Boost compensator adjustment_02

Pump speed r/min 100 100 100

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

U alpha soll V 2.86 2.86 2.86

Timer stroke mm 3.8 1.7 5.9

Boost compensator adjustment_03

Pump speed r/min 350 350 350

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

U alpha soll V 2.86 2.86 2.86

Timer stroke mm 8 5.9 10.1

Boost compensator adjustment_04

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.86 2.86 2.86

Timer stroke mm 9.9 9.6 10.2

Boost compensator adjustment_05

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 80 80 80

U alpha soll V 2.86 2.86 2.86

Timer stroke mm 6.3 4.8 7.8

Boost compensator adjustment_06

Pump speed r/min 2100 2100 2100

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

U alpha soll V 2.86 2.86 2.86

Timer stroke mm 11.35 10.9 11.8

Boost compensator adjustment_07

Pump speed r/min 2100 2100 2100

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

U alpha soll V 2.86 2.86 2.86

Timer stroke mm 0 0 0

Timer adjustment

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.86 2.86 2.86

Vtps V 0.77 0.35 1.19

Basic *

Timer adjustment_02

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.86 2.86 2.86

Vtps V 0.77 0.35 1.19

Timer adjustment_03

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.86 2.86 2.86

Vtps V 4.252 3.848 4.656

Speed control lever angle

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.86 2.86 2.86

Overflow quantity cm3/min 560 430 690

0000000901

Pump speed r/min 1250 1250 1250

U alpha soll + dU alpha soll V 2.86 2.86 2.86

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

Average injection quantity mm3/st. 78.4 77.9 78.9

Difference in delivery mm3/st. 4.5

Basic *

_02

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 1.99 1.99 1.99

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

Average injection quantity mm3/st. 14.6 11.6 17.6

Difference in delivery mm3/st. 2

Basic *

Remarks
Confirmation of difference in delivery

_03

Pump speed r/min 100 100 100

U alpha soll + dU alpha soll V 2.99 2.99 2.99

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

Average injection quantity mm3/st. 56.5 46.5 66.5

_04

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 1.99 1.99 1.99

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

Average injection quantity mm3/st. 14.6 11.6 17.6

_05

Pump speed r/min 400 400 400

U alpha soll + dU alpha soll V 2.63 2.63 2.63

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

Average injection quantity mm3/st. 45.8 43.3 48.3

_06

Pump speed r/min 500 500 500

U alpha soll + dU alpha soll V 2.56 2.56 2.56

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

Average injection quantity mm3/st. 47.2 44.7 49.7

_07

Pump speed r/min 600 600 600

U alpha soll + dU alpha soll V 2.54 2.54 2.54

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

Average injection quantity mm3/st. 48.8 46.3 51.3

_08

Pump speed r/min 750 750 750

U alpha soll + dU alpha soll V 2.8 2.8 2.8

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

Average injection quantity mm3/st. 67.9 65.4 70.4

_09

Pump speed r/min 1250 1250 1250

U alpha soll + dU alpha soll V 2.86 2.86 2.86

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

Average injection quantity mm3/st. 78.4 77.4 79.4

_10

Pump speed r/min 1500 1500 1500

U alpha soll + dU alpha soll V 2.77 2.77 2.77

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

Average injection quantity mm3/st. 73.8 71.3 76.3

_11

Pump speed r/min 2100 2100 2100

U alpha soll + dU alpha soll V 2.64 2.64 2.64

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

Average injection quantity mm3/st. 62.8 60.3 65.3

_12

Pump speed r/min 2650 2650 2650

U alpha soll + dU alpha soll V 1.93 1.93 1.93

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

Average injection quantity mm3/st. 23 20.5 25.5

Stop lever angle

Pump speed r/min 2100 2100 2100

U alpha soll + dU alpha soll V 2.64 2.64 2.64

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 2.86 2.86 2.86

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

0000001201

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.86 2.86 2.86

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

TCV connector assembly specification (1)Ensure the GE harness is not twisted at section A. (2)Refer to the figure for the direction of connector clip B. (3)Route the TCV harness in the direction indicated by the arrows in the figure and install the connector C.
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0000001701 HARNESS & CONNECTOR

Connector and binder assembly specification (1)For A's connector, adjust the position of the protective tube to L1 and install. (2)Assemble the connectors and clips in the order A, B, C, D, E, F and G. (3)Fix the GE cable and the FCV cable using the binder (C). (4)Clip the Q adjustment, the P/U and the TPS harnesses using clip G. A:G.E. Connector B:F.C.V. terminal C:Clip (be careful of installation direction) D:Q adjustment connector E:P/U Connector F:T.P.S. Connector G:Binder I:Protective tube
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L1=10+-5mm