Information injection-pump assembly
BOSCH
9 460 610 076
9460610076
ZEXEL
104749-2080
1047492080
Rating:
Cross reference number
BOSCH
9 460 610 076
9460610076
ZEXEL
104749-2080
1047492080
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
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
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
Right R
Injection timing adjustment
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
33
32.5
33.5
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2500
2500
2500
Average injection quantity
mm3/st.
13.2
9.7
16.7
Injection timing adjustment_03
Pump speed
r/min
2200
2200
2200
Average injection quantity
mm3/st.
33.1
31.1
35.1
Injection timing adjustment_04
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
33
32
34
Injection timing adjustment_05
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
33.2
31.2
35.2
Injection quantity adjustment
Pump speed
r/min
2500
2500
2500
Average injection quantity
mm3/st.
13.2
10.2
16.2
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
2800
2800
2800
Average injection quantity
mm3/st.
4
Governor adjustment
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
8.2
6.7
9.7
Difference in delivery
mm3/st.
2.5
Basic
*
Governor adjustment_02
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
8.2
6.2
10.2
Governor adjustment_03
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
4
Boost compensator adjustment
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
10
5
15
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
52
52
Difference in delivery
mm3/st.
3
Basic
*
Speed control lever angle
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF
Magnet OFF
0000000901
Pump speed
r/min
1000
1000
1000
Overflow quantity
cm3/min
348
216
480
Stop lever angle
Pump speed
r/min
900
900
900
Pressure
kPa
313.5
284
343
Pressure
kgf/cm2
3.2
2.9
3.5
Basic
*
Stop lever angle_02
Pump speed
r/min
900
900
900
Pressure
kPa
314
275
353
Pressure
kgf/cm2
3.2
2.8
3.6
Stop lever angle_03
Pump speed
r/min
1800
1800
1800
Pressure
kPa
520
481
559
Pressure
kgf/cm2
5.3
4.9
5.7
Stop lever angle_04
Pump speed
r/min
2200
2200
2200
Pressure
kPa
608
569
647
Pressure
kgf/cm2
6.2
5.8
6.6
0000001101
Pump speed
r/min
900
900
900
Timer stroke
mm
1.4
1.1
1.7
Basic
*
_02
Pump speed
r/min
900
900
900
Timer stroke
mm
1.4
1
1.8
_03
Pump speed
r/min
1800
1800
1800
Timer stroke
mm
5.1
4.5
5.7
_04
Pump speed
r/min
2200
2200
2200
Timer stroke
mm
7.25
6.7
7.8
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.8
5.7
5.9
MS dimension
mm
1.2
1.1
1.3
Control lever angle alpha
deg.
25
21
29
Control lever angle beta
deg.
41
36
46
Control lever angle gamma
deg.
11
10.5
11.5
Information:
Location of Components
Illustration 1 g06494607
Typical example
(A) DEF tank breather
(B) Heater relay
(C) DEF fast fill tank-mounted valve
(D) Plug heater
(E) Heated supply line
(F) DEF fast fill receiver
(G) DEF tank
Illustration 2 g06494608
(C) DEF fast fill tank-mounted valveThe ground level DEF fill system works much like the ground level fast fuel system. DEF fast fill tank-mounted valve (C) is mounted in DEF tank (G). Fast fill tank-mounted valve (C) has a piston that is normally closed with a spring.
Illustration 3 g06516649
(H) O-Ring seal
(J) Flow In
(K) Flow Out
(L) Back cavityNote: O-Ring seal (H) allows small amount of fluid flow.Note: The main flow through the valve is not shown.Note: During normal flow conditions there is no pressure built up in back cavity (L). Back cavity (L) is essentially "open to atmosphere".When filling, the DEF flow opens the piston, past the diverter shield and a portion flows through an orifice in the piston into the float area.
Illustration 4 g06516652
(L) Back cavity
(M) Rolling diaphragm
(N) O-Ring seal
(P) Drain holeNote: O-Ring seal (N) prevents any flow from back cavity (L).Note: Once the float rises, the pressure in back cavity (L) equals the pressure pushing the front of rolling diaphragm (M). Since the area behind rolling diaphragm (M) is greater than the area in front, along with the spring force, diaphragm (M) is held shut.When the tank level causes the float to rise high enough, the orifice is blocked, causing increased pressure on the piston until valve (C) closes. The increased pressure in the fill line then causes the nozzle attached to the receiver to shut off.The nozzle shuts off when the nozzle sees 172 to 200 kPa (25 to 29 psi) resistance. If pressure is not great enough from the source pump/supply at nozzle, there is not enough pressure built up in line between valve and nozzle to trigger nozzle shut off and DEF exits the breather-overfill.Targeted flow for the DEF supply pump should be 45 L/min (12 US gpm). Excessive flow can lead to premature shut-off of DEF nozzle.DEF tank valve (C), supply line (E), and DEF fast fill receiver (F) are electrically heated based on ambient temperature, battery, and alternator loads controlled through heater relay (B). For heated DEF hose repair kit, refer to Service Magazine, M0103829, "Repair Kits for Quick Connect Diesel Exhaust Fluid (DEF) Line Fittings Are Now Available for Certain Cat® Machine Engines".Note: If receiver (F) and supply line (E) on machine are drained for storage, the system must be refilled via the ground fill connection. The system is refilled to ensure that plug heater (D) in receiver (F) remains submerged in DEF fluid during the heating operation.
Plug heater (D) probe must be submerged at least 80% in DEF fluid to prevent overheating that could lead to plug heater (D) failing.
Illustration 1 g06494607
Typical example
(A) DEF tank breather
(B) Heater relay
(C) DEF fast fill tank-mounted valve
(D) Plug heater
(E) Heated supply line
(F) DEF fast fill receiver
(G) DEF tank
Illustration 2 g06494608
(C) DEF fast fill tank-mounted valveThe ground level DEF fill system works much like the ground level fast fuel system. DEF fast fill tank-mounted valve (C) is mounted in DEF tank (G). Fast fill tank-mounted valve (C) has a piston that is normally closed with a spring.
Illustration 3 g06516649
(H) O-Ring seal
(J) Flow In
(K) Flow Out
(L) Back cavityNote: O-Ring seal (H) allows small amount of fluid flow.Note: The main flow through the valve is not shown.Note: During normal flow conditions there is no pressure built up in back cavity (L). Back cavity (L) is essentially "open to atmosphere".When filling, the DEF flow opens the piston, past the diverter shield and a portion flows through an orifice in the piston into the float area.
Illustration 4 g06516652
(L) Back cavity
(M) Rolling diaphragm
(N) O-Ring seal
(P) Drain holeNote: O-Ring seal (N) prevents any flow from back cavity (L).Note: Once the float rises, the pressure in back cavity (L) equals the pressure pushing the front of rolling diaphragm (M). Since the area behind rolling diaphragm (M) is greater than the area in front, along with the spring force, diaphragm (M) is held shut.When the tank level causes the float to rise high enough, the orifice is blocked, causing increased pressure on the piston until valve (C) closes. The increased pressure in the fill line then causes the nozzle attached to the receiver to shut off.The nozzle shuts off when the nozzle sees 172 to 200 kPa (25 to 29 psi) resistance. If pressure is not great enough from the source pump/supply at nozzle, there is not enough pressure built up in line between valve and nozzle to trigger nozzle shut off and DEF exits the breather-overfill.Targeted flow for the DEF supply pump should be 45 L/min (12 US gpm). Excessive flow can lead to premature shut-off of DEF nozzle.DEF tank valve (C), supply line (E), and DEF fast fill receiver (F) are electrically heated based on ambient temperature, battery, and alternator loads controlled through heater relay (B). For heated DEF hose repair kit, refer to Service Magazine, M0103829, "Repair Kits for Quick Connect Diesel Exhaust Fluid (DEF) Line Fittings Are Now Available for Certain Cat® Machine Engines".Note: If receiver (F) and supply line (E) on machine are drained for storage, the system must be refilled via the ground fill connection. The system is refilled to ensure that plug heater (D) in receiver (F) remains submerged in DEF fluid during the heating operation.
Plug heater (D) probe must be submerged at least 80% in DEF fluid to prevent overheating that could lead to plug heater (D) failing.