104701-1003 ZEXEL 9 460 611 783 BOSCH INJECTION-PUMP ASSEMBLY 9460611783 1047011003 8971242462

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 611 783 9460611783

ZEXEL 104701-1003 1047011003

ISUZU 8971242462 8971242462

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Components :

0.	INJECTION-PUMP ASSEMBLY	104701-1003
1.	_
2.	FUEL INJECTION PUMP	104601-1003
3.	NUMBER PLATE	146966-4800
4.	_
5.	CAPSULE
6.	ADJUSTING DEVICE
7.	NOZZLE AND HOLDER ASSY	105158-2264
8.	Nozzle and Holder	8-97021-474-2
9.	Open Pre:MPa(Kqf/cm2)	14.7{150}
10.	NOZZLE-HOLDER	105088-1120
11.	NOZZLE	105007-1240

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]	146220-4420	CAM PLATE
30.	[1]	146600-3000	O-RING
31.	[1]	146300-1900	PUMP PLUNGER
32.	[1]	146301-0200	SLIDING PIECE
33/1.	[0]	146603-0700	SHIM D17.5&7.5T0.60
33/1.	[0]	146603-0800	SHIM D17.5&7.5T0.70
33/1.	[0]	146603-0900	SHIM D17.5&7.5T0.90
33/1.	[0]	146603-1000	SHIM D17.5&7.5T1.00
33/1.	[0]	146603-1100	SHIM D17.5&7.5T1.20
33/1.	[0]	146603-3600	SHIM D17.5&7.5T2.40
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]	146600-3000	O-RING
37.	[1]	479773-4320	TIMER PISTON SENSOR
37.	[1]	479773-4320	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
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]	146234-0120	GUIDE PIN
50.	[1]	146403-6620	HYDRAULIC HEAD
50.	[1]	146403-6620	HYDRAULIC HEAD
50.	[1]	146403-6620	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]	146440-0120	FITTING
60.	[3]	139106-0100	FLAT-HEAD SCREW
123.	[1]	146620-8800	FLAT-HEAD SCREW
130.	[1]	146421-0420	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]	139512-0500	GASKET
138.	[1]	148610-0620	INLET UNION
158.	[1]	146614-6900	SPACER BUSHING
200.	[1]	146206-0100	COILED SPRING
205.	[1]	029470-4030	WOODRUFF KEY
230.	[1]	148613-1420	BRACKET
236.	[1]	146620-2700	HEX-SOCKET-HEAD CAP SCREW
237.	[1]	146620-0200	HEX-SOCKET-HEAD CAP SCREW
240.	[1]	146688-0120	PULLING ELECTROMAGNET
240/8.	[1]	146600-1700	O-RING
243.	[1]	146621-1000	UNION NUT
245.	[3]	139512-0500	GASKET
246.	[1]	139812-0500	EYE BOLT
247.	[1]	146605-6120	INLET UNION
248.	[1]	146614-0200	SPACER BUSHING
275.	[1]	148612-0520	BRACKET
276.	[2]	010210-1640	HEX-SOCKET-HEAD CAP SCREW
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]	148530-0620	GOVERNOR;ELECTRIC
506.	[3]	146620-8900	FLAT-HEAD SCREW
515.	[1]	106144-1051	TIMING CONTROL VALVE
515/12.	[1]	161440-3800	O-RING
515/13.	[1]	161440-3700	O-RING
516.	[2]	010206-1440	HEX-SOCKET-HEAD CAP SCREW M6P1L14
531.	[1]	479773-7220	PULSE GENERATOR
531/6.	[1]	479773-6500	O-RING
800S.	[1]	148009-0220	PUMP HOUSING
800S/1/6.	[1]	146601-0700	PACKING RING
804S.	[1]	146232-0720	COMPRESSION SPRING
906.	[1]	146966-4800	NAMEPLATE

Include in #2:

104701-1003 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 460 611 783 9460611783

ZEXEL 104701-1003 1047011003

ISUZU 8971242462 8971242462

Zexel num

Bosch num

Firm num

Name

104701-1003
104701-1004

9 460 611 783

8971242462 ISUZU

INJECTION-PUMP ASSEMBLY
4JG2-TC 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 2.7 2.7 2.7

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 2.7 2.7 2.7

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 2.7 2.7 2.7

Pump chamber pressure kPa 588 549 627

Pump chamber pressure kgf/cm2 6 5.6 6.4

Governor adjustment_04

Pump speed r/min 1800 1800 1800

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

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 706 657 755

Pump chamber pressure kgf/cm2 7.2 6.7 7.7

Boost compensator adjustment

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.7 2.7 2.7

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 2.7 2.7 2.7

Timer stroke mm 2.5 0.4 4.6

Boost compensator adjustment_03

Pump speed r/min 500 500 500

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

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 7.5 5.4 9.6

Boost compensator adjustment_04

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.7 2.7 2.7

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 % 70 70 70

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 4.5 3.4 5.6

Boost compensator adjustment_06

Pump speed r/min 1800 1800 1800

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

U alpha soll V 2.7 2.7 2.7

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 2.7 2.7 2.7

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 2.7 2.7 2.7

Vtps V 0.51 0.382 0.638

Basic *

Timer adjustment_02

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.7 2.7 2.7

Vtps V 0.51 0.382 0.638

Timer adjustment_03

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.7 2.7 2.7

Vtps V 2.09 1.867 2.313

Speed control lever angle

Pump speed r/min 1000 1000 1000

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

U alpha soll V 2.7 2.7 2.7

Overflow quantity cm3/min 560 430 690

0000000901

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 2.86 2.86 2.86

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

Average injection quantity mm3/st. 84.4 83.9 84.9

Difference in delivery mm3/st. 4.5

Basic *

_02

Pump speed r/min 360 360 360

U alpha soll + dU alpha soll V 1.73 1.73 1.73

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

Average injection quantity mm3/st. 12.7 9.7 15.7

Difference in delivery mm3/st. 2

Basic *

Remarks
Confirmation of difference in delivery

_03

Pump speed r/min 1800 1800 1800

U alpha soll + dU alpha soll V 2.93 2.93 2.93

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

Average injection quantity mm3/st. 84.1 81.1 87.1

Difference in delivery mm3/st. 10

Basic *

Remarks
Confirmation of difference in delivery

_04

Pump speed r/min 100 100 100

U alpha soll + dU alpha soll V 2.86 2.86 2.86

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

Average injection quantity mm3/st. 81.8 71.8 91.8

_05

Pump speed r/min 360 360 360

U alpha soll + dU alpha soll V 1.73 1.73 1.73

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

Average injection quantity mm3/st. 12.7 9.2 16.2

_06

Pump speed r/min 500 500 500

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. 65.75 62.5 69

_07

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 2.86 2.86 2.86

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

Average injection quantity mm3/st. 84.4 83.4 85.4

_08

Pump speed r/min 1800 1800 1800

U alpha soll + dU alpha soll V 2.93 2.93 2.93

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

Average injection quantity mm3/st. 84.1 80.6 87.6

_09

Pump speed r/min 2300 2300 2300

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 1800 1800 1800

U alpha soll + dU alpha soll V 2.93 2.93 2.93

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 2.7 2.7 2.7

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 2.86 2.86 2.86

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 5.8 5.7 5.9

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

Connector and binder assembly specification (1)Assemble the connectors and clips in the order A, B, C, D, E, F and G. (2)Run A and B's connectors under C's harness at J and fix. (3)After confirming that A and B's harness is routed under C's harness, fix clip F. (4)Confirm that E's harness connector harness is routed above C's harness at K and then fix it. A:P/U Connector B:T.P.S. Connector C:G.E. Connector D:Q adjustment connector E:T.C.V. Connector F:Push type clip G:Clip for GE.
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Information:

Introduction
Injector height setting is extremely important during the engine assembly process. The recommended intervals that are specified in the Operation and Maintenance Manual must be followed.Problem
An issue has been identified with the correct injector height settings. Check the injector height. Bottoming of the fuel injector rocker arm may be caused by the injector height being to high or low. Bottoming of the fuel injector can create a crack at the nose of the fuel injector rocker arm through the first and second threads of the adjusting screw hole. Once the crack has started it can result in the breaking of the fuel injector rocker arm at the nose. Breaking of the fuel injector rocker arm will result in an immediate poor engine performance.Solution
Performing the recommended inspection of the fuel injector rocker arm at the specified intervals in the operation and maintenance manual is important. Inspect the height