104701-3001 ZEXEL 9 460 611 851 BOSCH INJECTION-PUMP ASSEMBLY 9460611851 1047013001

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Information injection-pump assembly

BOSCH 9 460 611 851 9460611851

ZEXEL 104701-3001 1047013001

Components :

0.	INJECTION-PUMP ASSEMBLY	104701-3001
1.	_
2.	FUEL INJECTION PUMP	104601-3001
3.	NUMBER PLATE	148636-0100
4.	_	479773-9820
5.	CAPSULE
6.	ADJUSTING DEVICE
7.	NOZZLE AND HOLDER ASSY	105148-1401
8.	Nozzle and Holder	ME201844
9.	Open Pre:MPa(Kqf/cm2)	14.7{150}
10.	NOZZLE-HOLDER	105078-0181
11.	NOZZLE	105007-1350

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]	148200-0520	DRIVE SHAFT
12/3.	[1]	146201-0000	WOODRUFF KEY
17.	[1]	146204-0000	PLAIN WASHER
20.	[1]	148210-0120	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]	146603-1100	SHIM D17.5&7.5T1.20
34.	[1]	146306-1800	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]	479773-9920	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
48/1.	[1]	146690-6000	SHIM D17&5.2T2.3
48/1.	[1]	146690-6100	SHIM D17&5.2T2.4
48/1.	[1]	146690-6200	SHIM
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 D17&5.2T2.8
48/1.	[1]	146690-6600	SHIM D17&5.2T2.9
48/1.	[1]	146690-6700	SHIM
48/1.	[1]	146690-6800	SHIM D17&5.2T3.1
48/1.	[1]	146690-6900	SHIM D17&5.2T3.2
48/1.	[1]	146690-7000	SHIM D17&5.2T3.3
48/1.	[1]	146690-7100	SHIM D17&5.2T3.4
48/1.	[1]	146690-7200	SHIM D17&5.2T0.4
48/1.	[1]	146690-7300	SHIM D17&5.2T0.6
48/1.	[1]	146690-7400	SHIM D17&5.2T0.7
48/1.	[1]	146690-7500	SHIM D17&5.2T1.9
48/1.	[1]	146690-7800	SHIM D17&5.2T0.2
49.	[2]	146234-0120	GUIDE PIN
50.	[1]	146403-6120	HYDRAULIC HEAD
50.	[1]	146403-6120	HYDRAULIC HEAD
50.	[1]	146403-6120	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]	146432-0700	COMPRESSION SPRING
58.	[4]	146440-0720	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]	146110-1120	CONTROL VALVE
135/5.	[1]	146114-0000	SPRING WASHER
136.	[1]	148120-0020	OVER FLOW VALVE
137.	[3]	139512-0500	GASKET
138.	[1]	146668-3220	INLET UNION
158.	[1]	146614-6900	SPACER BUSHING
200.	[1]	146206-0100	COILED SPRING
205.	[1]	029470-4030	WOODRUFF KEY
232.	[1]	148613-1920	BRACKET
234.	[1]	146620-2700	HEX-SOCKET-HEAD CAP SCREW
236.	[1]	146620-2700	HEX-SOCKET-HEAD CAP SCREW
237.	[1]	146620-0200	HEX-SOCKET-HEAD CAP SCREW
240.	[1]	146650-1220	PULLING ELECTROMAGNET
240/8.	[1]	146600-1700	O-RING
243.	[1]	146621-1000	UNION NUT
244.	[1]	148613-2420	BRACKET
245.	[3]	139512-0500	GASKET
246.	[1]	139812-0500	EYE BOLT
247.	[1]	146668-5220	INLET UNION
248.	[1]	146614-0200	SPACER BUSHING
282.	[1]	139006-4400	BLEEDER SCREW
504.	[1]	146649-5100	RESISTER
505.	[1]	148530-1420	GOVERNOR;ELECTRIC
506.	[3]	146620-8900	FLAT-HEAD SCREW
515.	[1]	106144-1040	TIMING CONTROL VALVE
515/12.	[1]	161440-3800	O-RING
515/13.	[1]	161440-3700	O-RING
516.	[2]	010206-1440	HEX-SOCKET-HEAD CAP SCREW M6P1L14
531.	[1]	479773-9820	PULSE GENERATOR
800S.	[1]	148009-0620	PUMP HOUSING
800S/1/6.	[1]	146601-0700	PACKING RING
800S/1/6.	[1]	146601-0700	PACKING RING
804S.	[1]	146232-0720	COMPRESSION SPRING
878S.	[1]	148600-1300	SEAL RING
906.	[1]	148636-0100	NAMEPLATE
908.	[1]	148621-0000	UNION NUT
910S.	[1]	146600-4520	PARTS SET
910S.	[1]	146600-4520	PARTS SET
911S.	[1]	479773-9820	PULSE GENERATOR
912S.	[1]	139508-0200	GASKET D11.4&8.2T1
913S.	[1]	146422-0300	BLEEDER SCREW
914S.	[1]	146699-0020	VALVE SET
914S.	[1]	146699-0020	VALVE SET
914S.	[1]	146699-0020	VALVE SET
916S.	[1]	025804-1610	WOODRUFF KEY
941.	[1]	148600-2500	O-RING
942.	[1]	148611-0000	PLATE
943.	[2]	148621-0200	PLAIN WASHER
944.	[2]	148621-0100	UNION NUT
945.	[1]	148615-0000	TOOTHED GEAR

Include in #2:

104701-3001 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 460 611 851 9460611851

ZEXEL 104701-3001 1047013001

Zexel num

Bosch num

Firm num

Name

104701-3001
104701-3002

9 460 611 851

INJECTION-PUMP ASSEMBLY
* K 11CL COVEC 4 COVEC

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 133 133 136

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 2.81 2.81 2.81

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 2.81 2.81 2.81

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 2.81 2.81 2.81

Pump chamber pressure kPa 588 549 627

Pump chamber pressure kgf/cm2 6 5.6 6.4

Governor adjustment_04

Pump speed r/min 2000 2000 2000

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

U alpha soll V 2.81 2.81 2.81

Pump chamber pressure kPa 726 677 775

Pump chamber pressure kgf/cm2 7.4 6.9 7.9

Boost compensator adjustment

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.81 2.81 2.81

Timer stroke mm 8.6 8.4 8.8

Basic *

Boost compensator adjustment_02

Pump speed r/min 100 100 100

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

U alpha soll V 2.81 2.81 2.81

Timer stroke mm 3 0.9 5.1

Boost compensator adjustment_03

Pump speed r/min 350 350 350

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

U alpha soll V 2.81 2.81 2.81

Timer stroke mm 6.3 4.2 8.4

Boost compensator adjustment_04

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.81 2.81 2.81

Timer stroke mm 8.6 8.3 8.9

Boost compensator adjustment_05

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.81 2.81 2.81

Timer stroke mm 3.6 2 5.2

Boost compensator adjustment_06

Pump speed r/min 1800 1800 1800

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

U alpha soll V 2.81 2.81 2.81

Timer stroke mm 9.75 9.3 10.2

Boost compensator adjustment_07

Pump speed r/min 2300 2300 2300

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

U alpha soll V 2.81 2.81 2.81

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 2.81 2.81 2.81

Vtps V 0.77 0.45 1.09

Basic *

Timer adjustment_02

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.81 2.81 2.81

Vtps V 0.77 0.45 1.09

Timer adjustment_03

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.81 2.81 2.81

Vtps V 3.704 3.3 4.108

Speed control lever angle

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.81 2.81 2.81

Overflow quantity cm3/min 560 430 690

0000000901

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 2.81 2.81 2.81

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

Average injection quantity mm3/st. 83.8 83.3 84.3

Difference in delivery mm3/st. 6

Basic *

_02

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 2.17 2.17 2.17

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

Average injection quantity mm3/st. 24.2 20.7 27.7

Difference in delivery mm3/st. 2.5

Basic *

Remarks
Confirmation of difference in delivery

_03

Pump speed r/min 100 100 100

U alpha soll + dU alpha soll V 3.15 3.15 3.15

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

Average injection quantity mm3/st. 68.2 58.2 78.2

_04

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 2.17 2.17 2.17

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

Average injection quantity mm3/st. 24.2 20.7 27.7

_05

Pump speed r/min 600 600 600

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. 62.1 59.1 65.1

_06

Pump speed r/min 750 750 750

U alpha soll + dU alpha soll V 2.5 2.5 2.5

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

Average injection quantity mm3/st. 59.3 56.3 62.3

_07

Pump speed r/min 800 800 800

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. 80.8 77.8 83.8

_08

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 2.81 2.81 2.81

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

Average injection quantity mm3/st. 83.8 82.8 84.8

_09

Pump speed r/min 1500 1500 1500

U alpha soll + dU alpha soll V 2.87 2.87 2.87

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

Average injection quantity mm3/st. 87.7 84.7 90.7

_10

Pump speed r/min 2000 2000 2000

U alpha soll + dU alpha soll V 2.72 2.72 2.72

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

Average injection quantity mm3/st. 74.8 71.8 77.8

_11

Pump speed r/min 2450 2450 2450

U alpha soll + dU alpha soll V 1.72 1.72 1.72

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

Average injection quantity mm3/st. 24.4 21.4 27.4

Stop lever angle

Pump speed r/min 2000 2000 2000

U alpha soll + dU alpha soll V 2.72 2.72 2.72

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 2.81 2.81 2.81

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 2.81 2.81 2.81

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 5.62 5.52 5.72

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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