104701-3003 ZEXEL 9 460 611 402 BOSCH INJECTION-PUMP ASSEMBLY 9460611402 1047013003


104701-3003 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 460 611 402 9460611402
ZEXEL 104701-3003 1047013003

Components :

0. INJECTION-PUMP ASSEMBLY 104701-3003
1. _
2. FUEL INJECTION PUMP 104601-3003
3. NUMBER PLATE 148641-0700
4. _ 479773-9821
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] 146600-0800 O-RING
31. [1] 146300-1900 PUMP PLUNGER
32. [1] 146301-0000 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] 146600-0800 O-RING
37. [1] 479773-9921 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
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 D17&5.2T2.8
48/1. [1] 146690-6600 SHIM D17&5.2T2.9
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
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
49. [2] 146234-0600 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] 146110-3220 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] 148613-2521 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. [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] 148530-1923 GOVERNOR;ELECTRIC
506. [3] 146620-8900 FLAT-HEAD SCREW
515. [1] 106144-1070 TIMING CONTROL VALVE
515/7. [1] 161440-3800 O-RING
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] 479773-9821 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] 146210-5720 ROLLER SET
878S. [1] 148600-1300 SEAL RING
906. [1] 148641-0700 NAMEPLATE
908. [1] 148621-0000 UNION NUT
910S. [1] 146600-4520 PARTS SET
910S. [1] 146600-4520 PARTS SET
911S. [1] 479773-9821 PULSE GENERATOR
911S/6. [1] 479773-6500 O-RING
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:

104701-3003 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 460 611 402 9460611402
ZEXEL 104701-3003 1047013003


Zexel num
Bosch num
Firm num
Name
104701-3003 
104701-3004 
9 460 611 402 
   
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

Test data 104701-3003
Compensation resistance/compensation voltage comparison A = Compensation resistor number B= Compensation resistance C = Compensation voltage delta U alpha soll
----------

----------

0000001601 HARNESS & CONNECTOR

Test data 104701-3003
Connector and binder assembly specification (1)To make routing the F.C.V. and T.C.V. harness easier, pull out the fixed side (C, towards F) before installing the GE connector. (2)Adjust the protective tube position to L1 and install the GE connector. (3)Route the F.C.V. harness between the brackets. (4)Assemble the connectors and clips in the order A, B, C, D, E, F, G, H, I and J. (5)Coat all around the O-ring with engine oil (corresponding to Mobil 1) to prevent O-ring damage, then assemble. A:G.E. Connector B:F.C.V. harness C:F.C.V. terminal D:G.E. and F.C.V. harness clip E:Q adjustment connector F:T.C.V. Connector G:TCV harness clip H:P/U Connector I:T.P.S. Connector J:Q adjustment, P/U and TCV harness clip K:O-Ring M:Protective tube
----------

----------
L1=23+-5mm

0000001701 HARNESS & CONNECTOR

Test data 104701-3003
Timing gear assembly standard A:Align the timing mark (aligning mark) by eye. B:When there is no mark for the gear installation position, align with the center of the pump's elongated hole. C:Gear tooth's standard position
----------

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L1=16.3mm T1=10~15N-m(1~1.5kgf-m) T2=59~69N-m(6~7kgf-m)




Have questions with 104701-3003?





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