Information injection-pump assembly
ZEXEL
104701-2010
1047012010
Rating:
Cross reference number
ZEXEL
104701-2010
1047012010
Zexel num
Bosch num
Firm num
Name
104701-2010
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
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
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
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
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
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
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
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
----------
----------
----------
----------
Information:
Crankcase Lubricating Oil
The Lubrication and Maintenance Charts list the normal oil change periods as determined by fuel sulphur content. (Make an initial oil change after the first 500 miles of operation for reconditioned engines.)Use oils which meet Engine Service classification CD or MIL-L-2104C. These are additive-type oils that have been approved for use in Caterpillar Diesel Engines. Diesel Engine Crankcase
Check oil level daily before starting engine and when refueling. Check with the engine either running or stopped as indicated on the oil level gauge. Add oil when the level drops to the add oil mark. Drain the crankcase every 10,000 miles while engine is warm and stopped. If equipped with a 13 qt. supplemental filter system the normal interval can be extended to 15,000 miles. Install drain plug. Diesel Engine Crankcase Lubricating Oil Filter
Change filter element every 10,000 miles. Drain the filter housing by removing drain plug. Loosen bolt on the cover and remove the housing and filter element. Inspect seal and install a new one if necessary. Wash the inside of the filter housing and install a new Caterpillar filter element. After draining crankcase remove filter cap and refill. See page 15 for quantity. Start engine and check for oil leaks at drain plug and filter housing. Diesel Engine Crankcase Breather
Remove breather tube cover and element. Wash with clean solvent or diesel fuel at each oil change period. Inspect seal and replace if necessary. Lubricating Grease
Use Multipurpose-type Grease which contains both 3 to 5% molybdenum disulfide conforming to MIL-M-7866, and a suitable corrosion inhibitor. NLGI No. 2 Grade is suitable for most temperatures. NLGI No. 1 or No. 0 are suitable for extremely low temperatures.Always clean fittings before lubricating.Fan Pulley Bearing
Lubricate every 10,000 miles. Lubricate through fitting until grease appears at relief fitting on front of fan hub. Wipe off excess grease. Water Pump Bearing
Lubricate every 10,000 miles. Lubricate through fitting until lubricant appears at relief fitting. Earlier engines have no relief fitting. Excess lubricant will appear at end of water pump shaft. Tachometer Drive
Lubricate every 10,000 miles. Remove plug. Install grease fitting and apply one stroke of lubricant through fitting.
The Lubrication and Maintenance Charts list the normal oil change periods as determined by fuel sulphur content. (Make an initial oil change after the first 500 miles of operation for reconditioned engines.)Use oils which meet Engine Service classification CD or MIL-L-2104C. These are additive-type oils that have been approved for use in Caterpillar Diesel Engines. Diesel Engine Crankcase
Check oil level daily before starting engine and when refueling. Check with the engine either running or stopped as indicated on the oil level gauge. Add oil when the level drops to the add oil mark. Drain the crankcase every 10,000 miles while engine is warm and stopped. If equipped with a 13 qt. supplemental filter system the normal interval can be extended to 15,000 miles. Install drain plug. Diesel Engine Crankcase Lubricating Oil Filter
Change filter element every 10,000 miles. Drain the filter housing by removing drain plug. Loosen bolt on the cover and remove the housing and filter element. Inspect seal and install a new one if necessary. Wash the inside of the filter housing and install a new Caterpillar filter element. After draining crankcase remove filter cap and refill. See page 15 for quantity. Start engine and check for oil leaks at drain plug and filter housing. Diesel Engine Crankcase Breather
Remove breather tube cover and element. Wash with clean solvent or diesel fuel at each oil change period. Inspect seal and replace if necessary. Lubricating Grease
Use Multipurpose-type Grease which contains both 3 to 5% molybdenum disulfide conforming to MIL-M-7866, and a suitable corrosion inhibitor. NLGI No. 2 Grade is suitable for most temperatures. NLGI No. 1 or No. 0 are suitable for extremely low temperatures.Always clean fittings before lubricating.Fan Pulley Bearing
Lubricate every 10,000 miles. Lubricate through fitting until grease appears at relief fitting on front of fan hub. Wipe off excess grease. Water Pump Bearing
Lubricate every 10,000 miles. Lubricate through fitting until lubricant appears at relief fitting. Earlier engines have no relief fitting. Excess lubricant will appear at end of water pump shaft. Tachometer Drive
Lubricate every 10,000 miles. Remove plug. Install grease fitting and apply one stroke of lubricant through fitting.
Have questions with 104701-2010?
Group cross 104701-2010 ZEXEL
104701-2010
INJECTION-PUMP ASSEMBLY