104749-6640 ZEXEL 9 460 615 030 BOSCH INJECTION-PUMP ASSEMBLY 9460615030 1047496640 8944277660

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Information injection-pump assembly

BOSCH 9 460 615 030 9460615030

ZEXEL 104749-6640 1047496640

ISUZU 8944277660 8944277660

Components :

0.	INJECTION-PUMP ASSEMBLY	104749-6640
1.	_
2.	FUEL INJECTION PUMP	104649-1990
3.	NUMBER PLATE
4.	_
5.	CAPSULE
6.	ADJUSTING DEVICE
7.	NOZZLE AND HOLDER ASSY	105158-2150
8.	Nozzle and Holder
9.	Open Pre:MPa(Kqf/cm2)	13.2(135)
10.	NOZZLE-HOLDER	105088-1080
11.	NOZZLE	105007-1061

Scheme ###:

1/6.	[1]	146601-0700	PACKING RING
6.	[1]	146100-0020	SUPPLY PUMP
9.	[1]	146103-0000	COVER
10.	[2]	139104-0000	FLAT-HEAD SCREW
12.	[1]	146200-0520	DRIVE SHAFT
12/1.	[1]	146200-0500	DRIVE SHAFT
12/2.	[1]	146201-0000	WOODRUFF KEY
12/3.	[2]	146202-0100	DAMPER
12/4.	[1]	146203-0000	TOOTHED GEAR
17.	[1]	146204-0000	PLAIN WASHER
20.	[1]	146210-0120	ROLLER SET
24.	[1]	146303-0100	BEARING PIN
25.	[1]	146304-0000	BEARING PIN
26.	[1]	146305-0000	CLAMPING BAND
27.	[1]	146205-0000	SLOTTED WASHER
29.	[1]	146220-0020	CAM PLATE
30.	[1]	146600-0800	O-RING
31.	[1]	146300-0600	PUMP PLUNGER
32.	[1]	146301-0000	SLIDING PIECE
33.	[1]	146690-2000	SHIM T0.6
34.	[1]	146302-3400	COMPRESSION SPRING
35/1.	[0]	146690-2000	SHIM T0.6
35/1.	[0]	146690-2100	SHIM T0.7
35/1.	[0]	146690-2200	SHIM
35/1.	[0]	146690-2300	SHIM T1.0
35/1.	[0]	146690-2400	SHIM T1.2
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]	146690-2500	SHIM
48/1.	[1]	146690-2600	SHIM
48/1.	[1]	146690-2700	SHIM
48/1.	[1]	146690-2800	SHIM
48/1.	[1]	146690-2900	SHIM
48/1.	[1]	146690-3000	SHIM
48/1.	[1]	146690-3100	SHIM
49.	[2]	146234-0020	GUIDE PIN
50.	[1]	146400-8420	HYDRAULIC HEAD
50.	[1]	146400-8420	HYDRAULIC HEAD
50.	[1]	146400-8420	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
52/1.	[1]	146420-5200	SHIM
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
52/1.	[1]	146420-5700	SHIM D9.5&3.0T1.86
52/1.	[1]	146420-5800	SHIM
54.	[4]	146433-0100	GASKET D12&6.4T1.00
55.	[4]	146430-0120	DELIVERY-VALVE ASSEMBLY
56.	[4]	146432-0000	COMPRESSION SPRING
58.	[4]	146440-0120	FITTING
60.	[3]	139106-0100	FLAT-HEAD SCREW
66.	[1]	146600-0100	O-RING
67.	[1]	146503-1720	GOVERNOR COVER
67/1.	[1]	146505-8122	GOVERNOR COVER
67/13.	[1]	146621-1700	UNION NUT
67/14.	[1]	146621-1700	UNION NUT
67/15.	[1]	146526-2800	BLEEDER SCREW
67/16.	[1]	146526-2800	BLEEDER SCREW
67/23.	[1]	146628-4620	BRACKET
67/24.	[2]	139106-0000	FLAT-HEAD SCREW
67/26.	[1]	146626-5420	BRACKET
67/64.	[1]	146629-8820	BRACKET
67/78.	[1]	146600-4400	SEAL RING
67/200.	[1]	139308-0300	PLAIN WASHER
67/200.	[1]	139308-0300	PLAIN WASHER
67/201.	[1]	146545-3720	THREADED PIN
67/202.	[1]	139208-0900	UNION NUT
67/203.	[1]	146600-1200	O-RING
68.	[1]	146510-9320	CONTROL SHAFT
69.	[1]	139310-0200	PLAIN WASHER
72.	[1]	146534-9520	CONTROL LEVER
72B.	[1]	146534-9620	CONTROL LEVER
73.	[1]	014110-6440	LOCKING WASHER
75.	[1]	146621-0700	UNION NUT
95.	[1]	146551-4620	FULCRUM LEVER
104.	[2]	146568-0000	SLOTTED SPRING PIN
105.	[2]	026508-1140	GASKET
106.	[2]	146588-0500	COILED SPRING
107.	[1]	146569-0300	UNION NUT
108.	[1]	146570-0420	GOVERNOR SHAFT
109.	[1]	146600-0400	O-RING
110/1.	[1]	146571-0000	SHIM D20.2&8.3T1.05
110/1.	[1]	146571-0100	SHIM D20.2&8.3T1.25
110/1.	[1]	146571-0200	SHIM D20.2&8.3T1.45
110/1.	[1]	146571-0300	SHIM D20.2&8.3T1.65
110/1.	[1]	146571-0400	SHIM D20.2&8.3T1.85
110/1.	[1]	146571-0500	SHIM D20.2&8.3T1.15
110/1.	[1]	146571-0600	SHIM D20.2&8.3T1.35
110/1.	[1]	146571-0700	SHIM D20.2&8.3T1.55
110/1.	[1]	146571-0800	SHIM D20.2&8.3T1.75
111.	[1]	146602-0600	PLAIN WASHER D20&8.4T1.40
112.	[1]	146572-0020	FLYWEIGHT ASSEMBLY
114.	[1]	146602-0500	PLAIN WASHER D17&6.4T1.60
115.	[1]	146575-3200	SLIDING SLEEVE
116.	[1]	146576-0000	SEALING CAP
117/1.	[1]	146577-1800	PLUG L2.10
117/1.	[1]	146577-1900	PLUG L2.30
117/1.	[1]	146577-2000	PLUG L2.50
117/1.	[1]	146577-2100	PLUG L2.70
117/1.	[1]	146577-2200	PLUG L2.90
117/1.	[1]	146577-2300	PLUG L3.10
117/1.	[1]	146577-2400	PLUG L3.30
117/1.	[1]	146577-2500	PLUG L3.50
117/1.	[1]	146577-2600	PLUG L3.70
117/1.	[1]	146577-2700	PLUG L3.90
117/1.	[1]	146577-2800	PLUG L4.10
117/1.	[1]	146577-2900	PLUG L4.30
117/1.	[1]	146577-3000	PLUG L4.50
117/1.	[1]	146577-3100	PLUG L4.70
117/1.	[1]	146577-3200	PLUG L4.90
117/1.	[1]	146577-3300	PLUG L5.10
117/1.	[1]	146577-6700	PLUG
117/1.	[1]	146577-6800	PLUG
117/1.	[1]	146577-6900	PLUG
117/1.	[1]	146577-7000	PLUG
117/1.	[1]	146577-7100	PLUG
117/1.	[1]	146577-7200	PLUG
117/1.	[1]	146577-7300	PLUG
117/1.	[1]	146577-7400	PLUG
117/1.	[1]	146577-7500	PLUG
117/1.	[1]	146577-7600	PLUG
117/1.	[1]	146577-7700	PLUG
117/1.	[1]	146577-7800	PLUG
117/1.	[1]	146577-7900	PLUG
117/1.	[1]	146577-8000	PLUG L4.8
117/1.	[1]	146577-8100	PLUG
117/1.	[1]	146877-0000	PLUG L5.2
117/1.	[1]	146877-0100	PLUG
117/1.	[1]	146877-0200	PLUG
117/1.	[1]	146877-0300	PLUG
117/1.	[1]	146877-4700	PLUG
117/1.	[1]	146877-4800	PLUG
117/1.	[1]	146877-4900	PLUG
117/1.	[1]	146877-5000	PLUG
123.	[4]	139106-0200	FLAT-HEAD SCREW
130.	[1]	146421-0020	CAPSULE
130/2.	[1]	026508-1140	GASKET
130/3.	[1]	146422-0000	BLEEDER SCREW
130/4.	[1]	146600-0500	O-RING
133.	[1]	146600-0600	O-RING
134.	[1]	146600-0700	O-RING
135.	[1]	146110-0920	CONTROL VALVE
135/5.	[1]	146114-0000	SPRING WASHER
136.	[1]	146120-0120	OVER FLOW VALVE
137.	[2]	026512-1540	GASKET D15.4&12.2T1.50
137.	[2]	026512-1540	GASKET D15.4&12.2T1.50
138.	[1]	146607-2920	INLET UNION
200.	[1]	146206-0100	COILED SPRING
205.	[1]	146201-0100	WOODRUFF KEY
220.	[1]	146587-7600	COILED SPRING
225.	[1]	146629-8920	BRACKET
230.	[1]	146628-1620	BRACKET
231.	[1]	139106-0500	FLAT-HEAD SCREW M6P1.0H25
237.	[1]	146620-0200	HEX-SOCKET-HEAD CAP SCREW
240.	[1]	146650-1220	PULLING ELECTROMAGNET
240/8.	[1]	146600-1700	O-RING
242.	[1]	146658-4620	WIRE
243.	[1]	146621-1000	UNION NUT
244.	[1]	146613-5620	PLATE
245.	[3]	026512-1840	GASKET D17.9&12.2T1.50
246.	[1]	146125-0000	EYE BOLT
247.	[1]	146606-7020	INLET UNION
248.	[1]	146614-0200	SPACER BUSHING
275.	[1]	146619-6220	BRACKET
276.	[2]	010010-2040	BLEEDER SCREW M10P1.5L20
277.	[2]	014111-0440	LOCKING WASHER
280.	[1]	146360-6120	START ADVANCE ASSY
281.	[1]	146600-0800	O-RING
282.	[1]	020306-1240	BLEEDER SCREW
286.	[1]	146659-4200	PLATE
287.	[1]	020106-3540	BLEEDER SCREW
310.	[1]	146673-4721	POTENTCIOMETER
455.	[1]	146549-4720	RACK
460.	[2]	016010-0440	LOCKING WASHER
461.	[1]	014010-4140	PLAIN WASHER D10&4.5T0.8
800S.	[1]	146019-5020	PUMP HOUSING
800S/1/6.	[1]	146601-0700	PACKING RING
804S.	[1]	146232-0320	COMPRESSION SPRING
805S.	[1]	146574-0120	PARTS SET
810S.	[1]	146600-1120	REPAIR SET
847S.	[1]	146684-3110	POTENTCIOMETER
903.	[1]	146672-2020	PULSE GENERATOR
903/2.	[1]	146600-1300	O-RING
906.	[1]	146646-7400	NAMEPLATE

Include in #2:

104749-6640 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 460 615 030 9460615030

ZEXEL 104749-6640 1047496640

ISUZU 8944277660 8944277660

Zexel num

Bosch num

Firm num

Name

104749-6640

9 460 615 030

8944277660 ISUZU

INJECTION-PUMP ASSEMBLY
4FC1J * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105000-2010

Bosch type code NP-DN12SD12TT

Nozzle holder 105780-2080

Opening pressure MPa 14.7 14.7 15.19

Opening pressure kgf/cm2 150 150 155

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840

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

Injection timing adjustment

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 40 39.5 40.5

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 41.7 36.7 46.7

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 38.6 33.6 43.6

Oil temperature degC 48 46 50

Injection timing adjustment_04

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 39 37.5 40.5

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 40 39 41

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 2250 2250 2250

Average injection quantity mm3/st. 35 33.5 36.5

Oil temperature degC 52 50 54

Injection timing adjustment_07

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 34.9 33.3 36.5

Difference in delivery mm3/st. 4.5

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2650 2650 2650

Average injection quantity mm3/st. 12 9 15

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2650 2650 2650

Average injection quantity mm3/st. 12 11 13

Difference in delivery mm3/st. 4

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8.8 6.8 10.8

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8.8 6.8 10.8

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 75 60 90

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 75 60 90

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1250 1250 1250

Overflow quantity cm3/min 420 290 550

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Pressure kPa 431 411 451

Pressure kgf/cm2 4.4 4.2 4.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Pressure kPa 431 411 451

Pressure kgf/cm2 4.4 4.2 4.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 2050 2050 2050

Pressure kPa 637 608 666

Pressure kgf/cm2 6.5 6.2 6.8

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke mm 3.9 3.7 4.1

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 630 530 730

Timer stroke mm 0.5 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Timer stroke mm 3.9 3.7 4.1

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1750 1750 1750

Timer stroke mm 6.6 6.2 7

Oil temperature degC 50 48 52

_05

Pump speed r/min 2050 2050 2050

Timer stroke mm 8.2 7.9 8.6

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 33 32.5 33.5

Timer stroke TA mm 3 3 3

Timer stroke variation dT mm 0.9 0.7 1.1

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 30 29 31

Timer stroke variation dT mm 0.9 0.5 1.3

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 25 24 26

Timer stroke variation dT mm 1.6 1.1 2.1

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 1.6 1.5 1.7

Control lever angle alpha deg. 24.5 20.5 28.5

Control lever angle beta deg. 40.5 35.5 45.5

Test data Ex:

0000001801 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. CSD adjusting screw adjustment Adjust so that the adjusting screw (A) protrusion is L1, then confirm. 2. Adjustment of the position of the intermediate lever. Insert a shim (J) between the control lever (I) and the FICD screw (E). Insert a shim L2 between the control lever (I) and the idle set screw (G). Align the intermediate lever (F) with the aligning line (K) and fix intermediate lever's adjusting screw (E) so that it contacts the control lever. 3. Adjustment of the FICD With the shim (J) inserted, insert a shim L2+-0.05 between the control lever (I) and the idle set screw (G). Use adjusting screw (B) to fix the CSD lever (C) in the position where it operates the intermediate lever via the rod (D). 4. Graph 2 Lever angle (deg) : theta =-0.1925t+6.65 3 lever position (mm) L=-0.0635t+2.19 3 shows the distance between the control lever and the idle set screw. X = temperature t (deg C) Y1 = timer stroke TA (mm) Y2 = control lever angle theta, L (deg, mm) (Z) = Cold advancer (R) = cooling water temperature (deg C) (S) = cooling water temperature: increase direction N = pump speed (U) = Lever angle (deg) (W) = Lever position (mm) (M) = standard point
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L1=10.2mm L2=0.92+-0.05mm (J)=2.8+-0.05mm
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L1=10.2mm L2=0.92+-0.05mm (J)=2.8+-0.05mm N1=100r/min a=20degC b=-20degC c=2.8+-1deg d=10.5+-3deg W1=0.9+-0.3mm W2=3.5+-1mm

0000001901 POTENTIOMETER ADJUSTMENT

Potentiometer adjustment (oval) N:Pump speed Vo:Output voltage Q:Injection quantity A:Adjusting point B:Target value Vi:Applied voltage
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N1=1000r/min N2=700r/min Q1=24.6+-1mm3/st Q2=(24.9+-2.5mm3/st) V1=5.4V V2=4.6V Vi=10V