104701-3030 ZEXEL 9 460 614 819 BOSCH INJECTION-PUMP ASSEMBLY 9460614819 1047013030


104701-3030 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 460 614 819 9460614819
ZEXEL 104701-3030 1047013030

Cross reference number

BOSCH 9 460 614 819 9460614819
ZEXEL 104701-3030 1047013030


Zexel num
Bosch num
Firm num
Name
104701-3030 
104701-3031 
9 460 614 819 
   
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   2.81 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
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.   20.2 16.7 23.7
Difference in delivery mm3/st.   2.5
Basic   *
Remarks
Confirmation of difference in delivery
 
_03
Pump speed r/min   800 800 800
U alpha soll + dU alpha soll V   2.82 2.82 2.82
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   87.6 84.6 90.6
Difference in delivery mm3/st.   6
Basic   *
Remarks
Confirmation of difference in delivery
 
_04
Pump speed r/min   100 100 100
U alpha soll + dU alpha soll V   3.16 3.16 3.16
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   75 65 85
_05
Pump speed r/min   100 100 100
U alpha soll + dU alpha soll V   2.71 2.71 2.71
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   38.5 28.5 48.5
_06
Pump speed r/min   200 200 200
U alpha soll + dU alpha soll V   2.71 2.71 2.71
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   45.8 39.8 51.8
_07
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.   20.2 16.7 23.7
_08
Pump speed r/min   400 400 400
U alpha soll + dU alpha soll V   2.66 2.66 2.66
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   56 53 59
_09
Pump speed r/min   500 500 500
U alpha soll + dU alpha soll V   2.67 2.67 2.67
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   64.9 61.9 67.9
_10
Pump speed r/min   750 750 750
U alpha soll + dU alpha soll V   2.6 2.6 2.6
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   67.9 64.9 70.9
_11
Pump speed r/min   800 800 800
U alpha soll + dU alpha soll V   2.82 2.82 2.82
TCV duty (%) F TCV 60Hz %   100 100 100
Average injection quantity mm3/st.   87.6 84.6 90.6
_12
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
_13
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.   89.3 86.3 92.3
_14
Pump speed r/min   1800 1800 1800
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.   80.5 77.5 83.5
_15
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.   76.1 73.1 79.1
_16
Pump speed r/min   2475 2475 2475
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.   25 22 28
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 104701-3030
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

Test data 104701-3030
TCV connector assembly specification (1)Ensure the GE cable 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

Test data 104701-3030
Corrugated tube assembly specification (1)Position the connector as shown in the figure, and maintain the dimensions shown in the figure for the end of the connector and the end of the corrugated tube. (2)Wrap black vinyl tape 4 times around the end of the corrugated tube to fix the tube. A:Corrugated tube J:PVC tape L4:Dimension from protective tube to end face of connector
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L1=90+-10mm L2=80+-10mm L3=110+-10mm L4=(20mm)

0000001801 HARNESS & CONNECTOR

Test data 104701-3030
Clip assembly standards (harness fixing) (1)Fix all the harnesses (GE cable, TCV, FCV, TPS, P/U, Q adjustment) using the clip. (2)Where the clip holds the harnesses, when fixing the clip to the bracket hole, fix where the GE cable contacts the bracket at J and K. (3)Be careful of the clip assembly direction because it is fixed to the bracket hole. (4)After clipping, cut off excess clip leaving L1. A:Binder B:Fix at bracket hole. C:Figure shown by arrow
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L1=(2mm)

0000001901 HARNESS & CONNECTOR

Test data 104701-3030
Timing gear assembly standard A:Paint mark for distinguishing position (above gear tooth with groove) B:Ideal center of grooved tooth for standard tooth position. C:Gear tooth's standard position D:Timing mark stamping
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L1=4mm L2=7.5mm L3=16.3mm T1=10~15N-m(1~1.5kgf-m) T2=59~69N-m(6~7kgf-m) a=(120deg) b=(27deg)




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