104721-2002 ZEXEL 9 460 611 584 BOSCH INJECTION-PUMP ASSEMBLY 9460611584 1047212002

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Information injection-pump assembly

BOSCH 9 460 611 584 9460611584

ZEXEL 104721-2002 1047212002

Components :

0.	INJECTION-PUMP ASSEMBLY	104721-2002
1.	_
2.	FUEL INJECTION PUMP	104621-2002
3.	NUMBER PLATE	148633-3900
4.	_
5.	CAPSULE
6.	ADJUSTING DEVICE	105141-8051
7.	NOZZLE AND HOLDER ASSY	105140-1191
8.	Nozzle and Holder	16600-VB300
9.	Open Pre:MPa(Kqf/cm2)	14.2{145}
10.	NOZZLE-HOLDER	105071-0681
11.	NOZZLE	105000-2290

Scheme ###:

1/6.	[1]	146601-0700	PACKING RING
6.	[1]	146100-0120	SUPPLY PUMP
9.	[1]	148103-0300	COVER
10.	[2]	139104-0000	FLAT-HEAD SCREW
12.	[1]	148200-0420	DRIVE SHAFT
12/1.	[1]	148200-0400	DRIVE SHAFT
12/2.	[1]	148203-0300	GEAR;SENSING
12/3.	[1]	146201-0000	WOODRUFF KEY
17.	[1]	146204-0000	PLAIN WASHER
20.	[1]	148210-0520	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]	146221-1620	CAM PLATE
30.	[1]	146600-0800	O-RING
31.	[1]	146300-0700	PUMP PLUNGER
32.	[1]	146301-0000	SLIDING PIECE
33.	[1]	146603-0700	SHIM D17.5&7.5T0.60
34.	[1]	146306-2200	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]	146310-0700	COVER
38.	[2]	146620-5000	BLEEDER 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
48/1.	[1]	146690-5900	SHIM
48/1.	[1]	146690-6000	SHIM
48/1.	[1]	146690-6100	SHIM
48/1.	[1]	146690-6200	SHIM
48/1.	[1]	146690-6300	SHIM
48/1.	[1]	146690-6400	SHIM
48/1.	[1]	146690-6500	SHIM
48/1.	[1]	146690-6600	SHIM
48/1.	[1]	146690-6700	SHIM
48/1.	[1]	146690-6800	SHIM
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
48/1.	[1]	146690-7400	SHIM
48/1.	[1]	146690-7500	SHIM
48/1.	[1]	146690-7800	SHIM
49.	[2]	146234-0600	GUIDE PIN
50.	[1]	146405-3720	HYDRAULIC HEAD
50.	[1]	146405-3720	HYDRAULIC HEAD
50.	[1]	146405-3720	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.	[6]	146433-0100	GASKET D12&6.4T1.00
55.	[6]	146430-6220	DELIVERY-VALVE ASSEMBLY
56.	[6]	146432-0000	COMPRESSION SPRING
58.	[6]	146440-2720	FITTING
60.	[4]	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]	139512-0200	GASKET D18.5&12.2T1.00
138.	[1]	146669-3620	INLET UNION
158.	[1]	146614-6900	SPACER BUSHING
200.	[1]	146206-0100	COILED SPRING
230.	[1]	148613-3120	BRACKET
236.	[2]	146620-2700	HEX-SOCKET-HEAD CAP SCREW
240.	[1]	146688-2620	PULLING ELECTROMAGNET
240/8.	[1]	146600-1700	O-RING
243.	[1]	146621-1000	UNION NUT
245.	[3]	139512-0200	GASKET D18.5&12.2T1.00
246.	[1]	139812-0500	EYE BOLT
247.	[1]	146669-1320	INLET UNION
248.	[1]	146614-0200	SPACER BUSHING
275.	[1]	148612-1200	BRACKET
276.	[2]	010010-2840	BLEEDER SCREW
278.	[2]	146616-8500	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]	148531-2121	GOVERNOR;ELECTRIC
506.	[3]	146620-8900	FLAT-HEAD SCREW
515.	[1]	106144-1061	TIMING CONTROL VALVE
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]	479773-4522	PULSE GENERATOR
531/6.	[1]	479773-6500	O-RING
800S.	[1]	148009-0720	PUMP HOUSING
800S/1/6.	[1]	146601-0700	PACKING RING
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
856S.	[1]	146600-4920	REPAIR SET
878S.	[1]	148600-1300	SEAL RING
906.	[1]	148633-3900	NAMEPLATE

Include in #2:

104721-2002 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 460 611 584 9460611584

ZEXEL 104721-2002 1047212002

Zexel num

Bosch num

Firm num

Name

104721-2002
104721-2003

9 460 611 584

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

Governor adjustment

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.3 2.3 2.3

Pump chamber pressure kPa 569 540 598

Pump chamber pressure kgf/cm2 5.8 5.5 6.1

Basic *

Governor adjustment_02

Pump speed r/min 100 100 100

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

U alpha soll V 2.3 2.3 2.3

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 2.3 2.3 2.3

Pump chamber pressure kPa 569 530 608

Pump chamber pressure kgf/cm2 5.8 5.4 6.2

Governor adjustment_04

Pump speed r/min 2200 2200 2200

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

U alpha soll V 2.3 2.3 2.3

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 % 70 70 70

U alpha soll V 2.3 2.3 2.3

Timer stroke mm 4.6 4.3 4.9

Basic *

Boost compensator adjustment_02

Pump speed r/min 500 500 500

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

U alpha soll V 2.3 2.3 2.3

Timer stroke mm 6.1 4.1 8.1

Boost compensator adjustment_03

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.3 2.3 2.3

Timer stroke mm 8.1 6.1 10.1

Boost compensator adjustment_04

Pump speed r/min 1000 1000 1000

TCV duty (%) F TCV 60Hz % 70 70 70

U alpha soll V 2.3 2.3 2.3

Timer stroke mm 4.6 4.3 4.9

Boost compensator adjustment_05

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.3 2.3 2.3

Timer stroke mm 0 0 0

Boost compensator adjustment_06

Pump speed r/min 1800 1800 1800

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

U alpha soll V 2.3 2.3 2.3

Timer stroke mm 8.95 8.5 9.4

Speed control lever angle

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.3 2.3 2.3

Overflow quantity cm3/min 520 390 650

0000000901

Pump speed r/min 1200 1200 1200

U alpha soll + dU alpha soll V 2.3 2.3 2.3

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

Average injection quantity mm3/st. 53 52.5 53.5

Difference in delivery mm3/st. 5.5

Basic *

_02

Pump speed r/min 320 320 320

U alpha soll + dU alpha soll V 1.9 1.9 1.9

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

Average injection quantity mm3/st. 11.3 8.3 14.3

Difference in delivery mm3/st. 2.5

Basic *

Remarks
Confirmation of difference in delivery

_03

Pump speed r/min 2700 2700 2700

U alpha soll + dU alpha soll V 1.8 1.8 1.8

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

Average injection quantity mm3/st. 25.6 23.1 28.1

Difference in delivery mm3/st. 5.5

Basic *

Remarks
Confirmation of difference in delivery

_04

Pump speed r/min 100 100 100

U alpha soll + dU alpha soll V 3 3 3

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

Average injection quantity mm3/st. 51.7 41.7 61.7

_05

Pump speed r/min 290 290 290

U alpha soll + dU alpha soll V 1.9 1.9 1.9

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

Average injection quantity mm3/st. 8.5 5.5 11.5

_06

Pump speed r/min 310 310 310

U alpha soll + dU alpha soll V 1.9 1.9 1.9

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

Average injection quantity mm3/st. 10.6 7.6 13.6

_07

Pump speed r/min 320 320 320

U alpha soll + dU alpha soll V 1.9 1.9 1.9

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

Average injection quantity mm3/st. 11.3 8.3 14.3

_08

Pump speed r/min 600 600 600

U alpha soll + dU alpha soll V 2 2 2

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

Average injection quantity mm3/st. 24.1 22.1 26.1

_09

Pump speed r/min 800 800 800

U alpha soll + dU alpha soll V 1.8 1.8 1.8

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

Average injection quantity mm3/st. 16.3 14.3 18.3

_10

Pump speed r/min 1200 1200 1200

U alpha soll + dU alpha soll V 1.8 1.8 1.8

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

Average injection quantity mm3/st. 21.3 19.3 23.3

_11

Pump speed r/min 1200 1200 1200

U alpha soll + dU alpha soll V 2.3 2.3 2.3

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

Average injection quantity mm3/st. 53 52 54

_12

Pump speed r/min 1600 1600 1600

U alpha soll + dU alpha soll V 1.9 1.9 1.9

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

Average injection quantity mm3/st. 30.6 28.1 33.1

_13

Pump speed r/min 2000 2000 2000

U alpha soll + dU alpha soll V 2.19 2.19 2.19

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

Average injection quantity mm3/st. 47.7 45.7 49.7

_14

Pump speed r/min 2400 2400 2400

U alpha soll + dU alpha soll V 2 2 2

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

Average injection quantity mm3/st. 36.2 33.7 38.7

_15

Pump speed r/min 2700 2700 2700

U alpha soll + dU alpha soll V 1.8 1.8 1.8

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

Average injection quantity mm3/st. 25.6 23.1 28.1

_16

Pump speed r/min 2700 2700 2700

U alpha soll + dU alpha soll V 1 1 1

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

Average injection quantity mm3/st. 3

Stop lever angle

Pump speed r/min 320 320 320

U alpha soll + dU alpha soll V 1.9 1.9 1.9

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

Average injection quantity cm3/min 3

Stop lever angle_02

Pump speed r/min 320 320 320

U alpha soll + dU alpha soll V 1.9 1.9 1.9

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

Average injection quantity cm3/min 7.6

Remarks
Each cylinder

Stop lever angle_03

Pump speed r/min 320 320 320

U alpha soll + dU alpha soll V 3 3 3

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

Average injection quantity cm3/min 0 0 0

Stop lever angle_04

Pump speed r/min 700 700 700

U alpha soll + dU alpha soll V 1.75 1.75 1.75

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

Average injection quantity cm3/min 0 0 0

Stop lever angle_05

Pump speed r/min 2400 2400 2400

U alpha soll + dU alpha soll V 3.5 3.5 3.5

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

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 2.3 2.3 2.3

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

0000001201

Pump speed r/min 1200 1200 1200

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

U alpha soll V 2.3 2.3 2.3

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 6.93 6.83 7.03

Pre-stroke mm 0.2 0.18 0.22

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

T.C.V. connector assembly specification (1)Ensure the GE harness is not twisted at section A. (2)Refer to diagram for direction of binder 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)Assemble the connectors and clips in the order A, B, C, D, E, F and G. (2)At clip position F (at the bracket hole) clip the F.C.V. harness and the G.E. cable, paying attention to the clip's installation direction. (3)Ensure the harness slack at J does not exceed L1. (4)At K, the protective tube and the bracket must contact so that the FCV harness does not directly contact the bracket. (5)Clip the GE (sub, main), the FCV, the TCV and the P/U harnesses using clip G. A:F.C.V., Q adjustment connector B:Q adjustment resistor C:G.E. Connector D:Push type clip E:P/U Connector F:Clip position (bracket hole) G:Binder H:T.C.V. Connector
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a=75deg L1=68mm L2=Max.27.5mm