104701-2013 ZEXEL 9 460 611 915 BOSCH INJECTION-PUMP ASSEMBLY 9460611915 1047012013

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 611 915 9460611915

ZEXEL 104701-2013 1047012013

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Components :

0.	INJECTION-PUMP ASSEMBLY	104701-2013
1.	_
2.	FUEL INJECTION PUMP	104601-2013
3.	NUMBER PLATE	148633-1300
4.	_
5.	CAPSULE
6.	ADJUSTING DEVICE	105148-8003
7.	NOZZLE AND HOLDER ASSY	105148-1221
8.	Nozzle and Holder	16600-63G01
9.	Open Pre:MPa(Kqf/cm2)	9.8{100}
10.	NOZZLE-HOLDER	105078-0050
11.	NOZZLE	105007-1210

Scheme ###:

1/6.	[1]	146601-0900	PACKING RING
6.	[1]	146100-0020	SUPPLY PUMP
9.	[1]	148103-0300	COVER
10.	[2]	139104-0000	FLAT-HEAD SCREW
12.	[1]	148200-0620	DRIVE SHAFT
12/3.	[1]	146201-0000	WOODRUFF KEY
17.	[1]	146204-0000	PLAIN WASHER
20.	[1]	148210-0220	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]	146220-4520	CAM PLATE
30.	[1]	146600-3000	O-RING
31.	[1]	146300-1900	PUMP PLUNGER
32.	[1]	146301-0200	SLIDING PIECE
33.	[1]	146603-0700	SHIM D17.5&7.5T0.60
34.	[1]	146306-2100	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]	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]	146234-0120	GUIDE PIN
50.	[1]	146403-6120	HYDRAULIC HEAD
50.	[1]	146403-6120	HYDRAULIC HEAD
50.	[1]	146403-6120	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]	146440-0220	FITTING
60.	[3]	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]	146110-3220	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]	146668-0420	INLET UNION
158.	[1]	146614-6900	SPACER BUSHING
200.	[1]	146206-0100	COILED SPRING
230.	[1]	148613-1220	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]	139512-0200	GASKET D18.5&12.2T1.00
246.	[1]	139812-0500	EYE BOLT
246.	[1]	139812-0500	EYE BOLT
247.	[1]	146668-3020	INLET UNION
248.	[1]	146614-0200	SPACER BUSHING
282.	[1]	139006-4400	BLEEDER SCREW
298.	[3]	146659-8000	CLAMPING BAND
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]	148531-1020	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]	479773-4521	PULSE GENERATOR
531/6.	[1]	479773-6500	O-RING
800S.	[1]	148009-0320	PUMP HOUSING
800S/1/6.	[1]	146601-0900	PACKING RING
804S.	[1]	146232-0720	COMPRESSION SPRING
878S.	[1]	148600-1300	SEAL RING
906.	[1]	148633-1300	NAMEPLATE

Include in #2:

104701-2013 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 460 611 915 9460611915

ZEXEL 104701-2013 1047012013

Zexel num

Bosch num

Firm num

Name

104701-2013
104701-2014

9 460 611 915

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 2.7 2.7 2.7

Pump chamber pressure kPa 617.5 588 647

Pump chamber pressure kgf/cm2 6.3 6 6.6

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 618 579 657

Pump chamber pressure kgf/cm2 6.3 5.9 6.7

Governor adjustment_04

Pump speed r/min 2000 2000 2000

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

U alpha soll V 2.7 2.7 2.7

Pump chamber pressure kPa 755 706 804

Pump chamber pressure kgf/cm2 7.7 7.2 8.2

Boost compensator adjustment

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 4.1 3.9 4.3

Basic *

Boost compensator adjustment_02

Pump speed r/min 500 500 500

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

U alpha soll V 2.7 2.7 2.7

Timer stroke mm 7.4 5.4 9.4

Boost compensator 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

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 2.7 2.7 2.7

Timer stroke mm 4.1 3.8 4.4

Boost compensator adjustment_05

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

Timer stroke mm 0 0 0

Boost compensator adjustment_06

Pump speed r/min 1500 1500 1500

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

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 600 470 730

0000000901

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 2.8 2.8 2.8

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

Average injection quantity mm3/st. 80.5 80 81

Difference in delivery mm3/st. 5

Basic *

_02

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 1.89 1.89 1.89

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

Average injection quantity mm3/st. 7 4 10

Difference in delivery mm3/st. 2

Basic *

Remarks
Confirmation of difference in delivery

_03

Pump speed r/min 2500 2500 2500

U alpha soll + dU alpha soll V 1.66 1.66 1.66

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

Average injection quantity mm3/st. 16.1 13.6 18.6

Difference in delivery mm3/st. 5

Basic *

Remarks
Confirmation of difference in delivery

_04

Pump speed r/min 100 100 100

U alpha soll + dU alpha soll V 3.5 3.5 3.5

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

Average injection quantity mm3/st. 83.3 73.3 93.3

_05

Pump speed r/min 375 375 375

U alpha soll + dU alpha soll V 1.89 1.89 1.89

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

Average injection quantity mm3/st. 7 4 10

_06

Pump speed r/min 500 500 500

U alpha soll + dU alpha soll V 2.49 2.49 2.49

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

Average injection quantity mm3/st. 50.1 48.1 52.1

_07

Pump speed r/min 800 800 800

U alpha soll + dU alpha soll V 1.86 1.86 1.86

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

Average injection quantity mm3/st. 15.4 13.4 17.4

_08

Pump speed r/min 800 800 800

U alpha soll + dU alpha soll V 2.62 2.62 2.62

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

Average injection quantity mm3/st. 64.4 62.4 66.4

_09

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 1.85 1.85 1.85

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

Average injection quantity mm3/st. 16.6 14.6 18.6

_10

Pump speed r/min 1000 1000 1000

U alpha soll + dU alpha soll V 2.8 2.8 2.8

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

Average injection quantity mm3/st. 80.5 79.5 81.5

_11

Pump speed r/min 2000 2000 2000

U alpha soll + dU alpha soll V 2.58 2.58 2.58

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

Average injection quantity mm3/st. 63.7 61.7 65.7

_12

Pump speed r/min 2250 2250 2250

U alpha soll + dU alpha soll V 2.43 2.43 2.43

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

Average injection quantity mm3/st. 54.3 51.8 56.8

_13

Pump speed r/min 2500 2500 2500

U alpha soll + dU alpha soll V 1.66 1.66 1.66

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

Average injection quantity mm3/st. 16.1 13.6 18.6

_14

Pump speed r/min 2500 2500 2500

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 375 375 375

U alpha soll + dU alpha soll V 1.89 1.89 1.89

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

Average injection quantity cm3/min 0 0 0

Stop lever angle_02

Pump speed r/min 2250 2250 2250

U alpha soll + dU alpha soll V 2.43 2.43 2.43

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 2.8 2.8 2.8

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

Connector and binder assembly specification (1)Install the connector as shown in the figure. (2)At the clip position at J (bracket's groove position), clip the F.C.V. harness and the G.E. harness together horizontally. (3)After clipping, the GE harness and the FCV harness must be within L1 from the pump flange face. A:P/U Connector B:F.C.V. connector, Q adjustment connector C:G.E. Connector D:Binder E:Q adjustment connector F:Bracket groove G:Clip position H:Push type clip I:T.C.V. Connector J:Position the GE harness and the FCV harness together horizontally. K:Pump flange face
----------

----------
L1=Max.207mm

Information:

PRIMARY FUEL FILTERFINAL FUEL FILTER ELEMENT: The filter element collects and holds contaminants and cannot be washed or otherwise restored. To remove the used filter element, proceed as follows:1. Stop the engine and close the diesel fuel line valve (if equipped).2. Unscrew and remove filter.3. Clean the gasket sealing surface on the filter base.
Do not pour fuel into the new filter elements before installing. Prime the system as instructed in the topic, PRIMING THE FUEL SYSTEM.
4. Lubricate the filter gasket with clean diesel fuel.5. Tighten the filter by hand, only tight enough to prevent leaks. (Do not overtighten.)6. Prime the fuel system. Refer to the topic "PRIMING THE FUEL SYSTEM"
REMOVING FUEL FILTER ELEMENT KEEP A NEW FUEL FILTER ON HAND: An extra filter should be kept on hand for replacement. Always keep the filter wrapped in its original carton to insure against dust and dirt accumulation which will shorten the life of the filter or may cause damage to the fuel injection equipment.PRIMING THE FUEL SYSTEM: Any time the fuel flow is broken and air is allowed to get into the fuel system, the system must be primed. If air is left in the lines, the fuel system may become air bound, resulting in inability to start the engine or the misfiring of one or more cylinders.
PRIMING THE FUEL SYSTEMThe fuel priming pump is mounted on the fuel filter housing as shown. If only the fuel filter is changed follow steps 1 through 5. If the fuel system is completely drained or if the engine has run out of fuel continue with steps through 10.1. Check to see that the fuel line valve is open.2. Open the fuel filter vent valve on the fuel filter housing.3. Loosen the knob of the fuel priming pump.4. Operate the pump plunger in and out until the flow of fuel from the vent valve is continuous and free of air bubbles.5. Close vent valve.6. Move governor control to the shut-off position and loosen fuel line nuts (one at a time) at the pump housing.7. Operate priming pump until clear fuel flows from the fuel pump lines. Tighten fuel line nut.8. Repeat for each fuel pump.9. Lock the knob of the fuel priming pump to its original position.10. Start the engine. If the engine does not run smoothly further bleeding may be necessary. With the engine running, open and close the fuel injection line nuts, one at a time, several times in succession to be sure all the air is bled from the system. Tighten fuel line nuts to 30 lbs.ft. (4,1 mkg). Do not overtighten.Fuel Injection Equipment
When improper fuel injection is affecting engine operation, a systematic check should be made to determine the cause. The most likely cause is dirt or water in the fuel. Drain the sediment from the fuel tank. Check the fuel pressure gauge as mentioned in the topic, FUEL FILTERING SYSTEM. Replace the filter element if necessary. Then prime the fuel system until clean fuel reaches the fuel