Information injection-pump assembly
ZEXEL
104740-0180
1047400180
MAZDA
481813800
481813800
Rating:
Cross reference number
ZEXEL
104740-0180
1047400180
MAZDA
481813800
481813800
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
(Note)
For Japan: year/month/day (change sequence) 1988/08/05 (1)
For Japan: year/month/day (change sequence) 1988/08/05 (1)
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
750
750
750
Average injection quantity
mm3/st.
44
43.5
44.5
Difference in delivery
mm3/st.
2.5
Basic
*
Injection timing adjustment_02
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
14.4
11.4
17.4
Injection timing adjustment_03
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
44
43
45
Injection timing adjustment_04
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
40.9
38.9
42.9
Injection timing adjustment_05
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
43
42.5
43.5
Difference in delivery
mm3/st.
2.5
Basic
*
Remarks
For Japan
For Japan
Injection timing adjustment_06
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
14.1
11.1
17.1
Remarks
For Japan
For Japan
Injection timing adjustment_07
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
43
42
44
Remarks
For Japan
For Japan
Injection timing adjustment_08
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
39.9
37.9
41.9
Remarks
For Japan
For Japan
Injection quantity adjustment
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
14.4
12.4
16.4
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
860
860
860
Average injection quantity
mm3/st.
4.1
Injection quantity adjustment_03
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
14.1
11.1
17.1
Basic
*
Remarks
For Japan
For Japan
Injection quantity adjustment_04
Pump speed
r/min
860
860
860
Average injection quantity
mm3/st.
4
Remarks
For Japan
For Japan
Governor adjustment
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
6.4
4.4
8.4
Difference in delivery
mm3/st.
2
Basic
*
Governor adjustment_02
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
6.4
4.4
8.4
Governor adjustment_03
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
6.2
4.2
8.2
Difference in delivery
mm3/st.
2
Basic
*
Remarks
For Japan
For Japan
Governor adjustment_04
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
6.2
4.2
8.2
Remarks
For Japan
For Japan
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
80.4
80.4
Basic
*
Timer adjustment_02
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
78
78
Basic
*
Remarks
For Japan
For Japan
Speed control lever angle
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF
Magnet OFF
Speed control lever angle_02
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
0
0
0
Remarks
For Japan: Magnet OFF
For Japan: Magnet OFF
0000000901
Pump speed
r/min
750
750
750
Overflow quantity
cm3/min
420
288
552
_02
Pump speed
r/min
750
750
750
Overflow quantity
cm3/min
420
288
552
Remarks
For Japan
For Japan
Stop lever angle
Pump speed
r/min
750
750
750
Pressure
kPa
343.5
314
373
Pressure
kgf/cm2
3.5
3.2
3.8
Basic
*
Stop lever angle_02
Pump speed
r/min
500
500
500
Pressure
kPa
255
226
284
Pressure
kgf/cm2
2.6
2.3
2.9
Stop lever angle_03
Pump speed
r/min
750
750
750
Pressure
kPa
343.5
314
373
Pressure
kgf/cm2
3.5
3.2
3.8
Stop lever angle_04
Pump speed
r/min
750
750
750
Pressure
kPa
333.5
304
363
Pressure
kgf/cm2
3.4
3.1
3.7
Basic
*
Remarks
For Japan
For Japan
Stop lever angle_05
Pump speed
r/min
500
500
500
Pressure
kPa
245.5
216
275
Pressure
kgf/cm2
2.5
2.2
2.8
Remarks
For Japan
For Japan
Stop lever angle_06
Pump speed
r/min
750
750
750
Pressure
kPa
333.5
304
363
Pressure
kgf/cm2
3.4
3.1
3.7
Remarks
For Japan
For Japan
0000001101
Pump speed
r/min
750
750
750
Timer stroke
mm
1.2
1
1.4
Basic
*
_02
Pump speed
r/min
750
750
750
Timer stroke
mm
1.2
0.9
1.5
_03
Pump speed
r/min
750
750
750
Timer stroke
mm
1.2
1
1.4
Basic
*
Remarks
For Japan
For Japan
_04
Pump speed
r/min
750
750
750
Timer stroke
mm
1.7
1.5
1.9
Remarks
For Japan
For Japan
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
Control lever angle alpha
deg.
10
6
14
Control lever angle beta
deg.
24
19
29
Information:
This Program must be administered either before or after failure.In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42850" as the Part Numberand "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
The information supplied in this service letter may not be valid after the termination date of this program.Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
TERMINATION DATE
31Dec2010
PROBLEM
The existing 153-8920 Injector Wire Harness can be too long on certain 3126B Engines. If the existing 153-8920 Injector Wire Harness fails it can cause the injectors to not function.
AFFECTED PRODUCT
Model Identification Number
DV-3304B BDZ01232, 1246-1248, 1250, 1253, 1256-1259, 1261, 1264-1274, 1276-1277, 1279-1283, 1286, 1292, 1294, 1299-1301, 1303-1315, 1340, 1349-1350, 1362, 1364, 1367, 1369, 1410, 1414-1415, 1417, 1421-1422, 1489, 1559, 1561-1563, 1572, 1574-1577, 1580-1586, 1591-1595, 1597-1610, 1612, 1614-1635, 1637, 1642-1648, 1650-1652, 1654-1680, 1686-1690, 1696-1698
PARTS NEEDED
Qty
Part Number Description
1 1538920 HARNESS AS.-WRG (As Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Refer to Disassembly and Assembly Manual SENR9589.
Remove the valve cover.
Inspect the injector wire harness. Ensure the injector wire harness does not interfere with the valve springs or other components.
Replace the injector wire harness if the harness is damaged.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-500 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 0.5-hour job
If the injector wire harness needs to be replace, an extra 3 hours of labor is allowed.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.