104701-2000 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047012000

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104701-2000 1047012000

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Cross reference number

ZEXEL 104701-2000 1047012000

Zexel num

Bosch num

Firm num

Name

104701-2000

INJECTION-PUMP ASSEMBLY

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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Information:

Table 1
Part Number Part Description Qty
378-3187 Diesel Exhaust Fluid Filter Gp 1
423-3251 Connector 1
391-5262 Gasket 1
425-0385 Filter As 1
452-6055 Filter Base As 1
453-1604(1) Diesel Exhaust Fluid Filter Gp 1
453-1605(1) Diesel Exhaust Fluid Filter Gp 1
453-1606(1) Diesel Exhaust Fluid Filter Gp 1
(1) Use Table 2 to choose the correct part that corresponds to the DEF heater
Table 2
DEF Heater Part Number Required DEF Filter
434-3241 453-1604
434-3242 453-1605
434-3243 453-1606 The effective serial numbers for this change are related to the Pump Electronic Tank Unit (PETU) serial numbers and not the machine serial numbers. Table 3 contains the effective serial numbers for the PETU tank. Refer to illustration 1 and illustration 2 for examples of where to locate the PETU serial number.
Illustration 1 g06018843
Typical example
(1) The location of the PETU serial plate.
Illustration 2 g03418749
Typical example
Table 3
PETU Effective Serial Numbers
S/N:PET007086T-UP Refer to Special Instruction, M0066142, A New Diesel Exhaust Fluid Filter is Now Available for C7.1 Engines for installation instructions.