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

Information Cross number Calibration Data Calibration Data Ex

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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

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 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

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

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

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)