Information injection-pump assembly
ZEXEL
104740-0020
1047400020
Rating:
Cross reference number
ZEXEL
104740-0020
1047400020
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
1000
1000
1000
Average injection quantity
mm3/st.
55.5
55
56
Difference in delivery
mm3/st.
4
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2000
2000
2000
Average injection quantity
mm3/st.
13
10
16
Injection timing adjustment_03
Pump speed
r/min
1800
1800
1800
Average injection quantity
mm3/st.
49
47
51
Injection timing adjustment_04
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
55.5
54.5
56.5
Injection timing adjustment_05
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
47.9
45.9
49.9
Injection quantity adjustment
Pump speed
r/min
2000
2000
2000
Average injection quantity
mm3/st.
13
11
15
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
2100
2100
2100
Average injection quantity
mm3/st.
5
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
12.7
10.7
14.7
Difference in delivery
mm3/st.
2.5
Basic
*
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
12.7
10.7
14.7
Governor adjustment_03
Pump speed
r/min
620
Average injection quantity
mm3/st.
0
0
0
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
78
78
Basic
*
Speed control lever angle
Pump speed
r/min
350
350
350
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
456
324
588
Stop lever angle
Pump speed
r/min
1500
1500
1500
Pressure
kPa
578.5
549
608
Pressure
kgf/cm2
5.9
5.6
6.2
Basic
*
Stop lever angle_02
Pump speed
r/min
500
500
500
Pressure
kPa
245.5
216
275
Pressure
kgf/cm2
2.5
2.2
2.8
Stop lever angle_03
Pump speed
r/min
1500
1500
1500
Pressure
kPa
578.5
549
608
Pressure
kgf/cm2
5.9
5.6
6.2
Stop lever angle_04
Pump speed
r/min
1800
1800
1800
Pressure
kPa
696.5
667
726
Pressure
kgf/cm2
7.1
6.8
7.4
0000001101
Pump speed
r/min
1500
1500
1500
Timer stroke
mm
5.2
5
5.4
Basic
*
_02
Pump speed
r/min
1000
1000
1000
Timer stroke
mm
2.5
1.9
3.1
_03
Pump speed
r/min
1500
1500
1500
Timer stroke
mm
5.2
4.9
5.5
_04
Pump speed
r/min
2000
2000
2000
Timer stroke
mm
7.45
7.1
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
1.6
1.5
1.7
Pre-stroke
mm
0.1
0.08
0.12
Control lever angle alpha
deg.
10
6
14
Control lever angle beta
deg.
39
34
44
Test data Ex:
0000001801 MICROSWITCH ADJUSTMENT
Microswitch adjustment
With the clearance between the idle stopper bolt (set at the idle setting) and the control lever set at L, adjust the control lever adjusting screw so that it contacts the head of the microswitch plunger.
----------
L=1.8mm
----------
----------
L=1.8mm
----------
Information:
Installation Procedure
Illustration 1 g06123834
Remove support (1) from the engine compartment.
Illustration 2 g06123840
Locate insulation (2) on the engine hood.
Illustration 3 g06123843
Raise the insulation approximately 30 mm (1.2 inch) to avoid interference with the new tank.
Illustration 4 g06123848
Loosen the worm-drive clamps and remove two hoses (3) from the DEF system. Save the cushion clamps and hardware for reuse.
Illustration 5 g06123850
(4) 428-8808 Hose Clamp
(5) 467-9633 Hose
(6) Cushion clamp (reuse)
Install hose (5) and two clamps (4). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in). Install cushion clamp (6) (previously removed) onto the hose.
Illustration 6 g06123852
(4) 428-8808 Hose Clamp
(6) Cushion clamp (reuse)
(7) 469-6277 Hose
(8) 424-1209 Tank
Connect one end of hose (7) to the tube on the engine using clamp (4). Slowly tighten the clamp to 6.6 0.2 N m (58 1.8 lb in). Install cushion clamp (6) (previously removed) onto the hose.
Connect the other end of the hose to the upper port on tank (8). Install clamp (4). Slowly tighten the clamp to 6.6 0.2 N m (58 1.8 lb in).
Illustration 7 g06123862
(4) 428-8808 Hose Clamp
(9) 469-9636 Hose
(10) 6V-3250 O-Ring Seal
(11) 7X-1448 Elbow
Install elbow (11) and O-Ring seal (10) on the tank. Install hose (9) using two hose clamps (4). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in) while ensuring hose (9) stays at a 30 degree angle from the top tank hose.
Illustration 8 g06123868
(12) 454-4235 Plate
(13) 326-4516 Cable Tie
Secure the two hoses together using plate (12) and two cable ties (13).
Illustration 9 g06123873
(8) 424-1209 Tank
(14) 471-9825 Support As
(15) 8T-4189 Bolt
(16) 8T-4224 Hard Washer
Install support (14) in place of the original support.
Secure tank (8) to the support using two bolts (15) and two washers (16).
Install new machine, engine, and after treatment software.The new software is available in the form of a flash file through the Caterpillar Service Information System (SIS). A newer part number may be available. SIS web only displays the latest available flash file.
Illustration 10 g06123878
Update the DES threshold to 525 degrees C using Cat® Electronic Technician (Cat ET). A factory password is required to change the value. A factory password can be obtained after inputting your Corporate Web Security (CWS) identification.
Illustration 1 g06123834
Remove support (1) from the engine compartment.
Illustration 2 g06123840
Locate insulation (2) on the engine hood.
Illustration 3 g06123843
Raise the insulation approximately 30 mm (1.2 inch) to avoid interference with the new tank.
Illustration 4 g06123848
Loosen the worm-drive clamps and remove two hoses (3) from the DEF system. Save the cushion clamps and hardware for reuse.
Illustration 5 g06123850
(4) 428-8808 Hose Clamp
(5) 467-9633 Hose
(6) Cushion clamp (reuse)
Install hose (5) and two clamps (4). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in). Install cushion clamp (6) (previously removed) onto the hose.
Illustration 6 g06123852
(4) 428-8808 Hose Clamp
(6) Cushion clamp (reuse)
(7) 469-6277 Hose
(8) 424-1209 Tank
Connect one end of hose (7) to the tube on the engine using clamp (4). Slowly tighten the clamp to 6.6 0.2 N m (58 1.8 lb in). Install cushion clamp (6) (previously removed) onto the hose.
Connect the other end of the hose to the upper port on tank (8). Install clamp (4). Slowly tighten the clamp to 6.6 0.2 N m (58 1.8 lb in).
Illustration 7 g06123862
(4) 428-8808 Hose Clamp
(9) 469-9636 Hose
(10) 6V-3250 O-Ring Seal
(11) 7X-1448 Elbow
Install elbow (11) and O-Ring seal (10) on the tank. Install hose (9) using two hose clamps (4). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in) while ensuring hose (9) stays at a 30 degree angle from the top tank hose.
Illustration 8 g06123868
(12) 454-4235 Plate
(13) 326-4516 Cable Tie
Secure the two hoses together using plate (12) and two cable ties (13).
Illustration 9 g06123873
(8) 424-1209 Tank
(14) 471-9825 Support As
(15) 8T-4189 Bolt
(16) 8T-4224 Hard Washer
Install support (14) in place of the original support.
Secure tank (8) to the support using two bolts (15) and two washers (16).
Install new machine, engine, and after treatment software.The new software is available in the form of a flash file through the Caterpillar Service Information System (SIS). A newer part number may be available. SIS web only displays the latest available flash file.
Illustration 10 g06123878
Update the DES threshold to 525 degrees C using Cat® Electronic Technician (Cat ET). A factory password is required to change the value. A factory password can be obtained after inputting your Corporate Web Security (CWS) identification.