104740-0200 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047400200 483413800

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-0200 1047400200

MAZDA 483413800 483413800

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Cross reference number

ZEXEL 104740-0200 1047400200

MAZDA 483413800 483413800

Zexel num

Bosch num

Firm num

Name

104740-0200
104740-0202

483413800 MAZDA

INJECTION-PUMP ASSEMBLY
NEWHA *

Calibration Data:

Adjustment conditions

(Note)
For Japan: year/month/day (change sequence) 1988/08/05 (1)

Test oil
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

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

Injection timing adjustment

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 52.25 49.5 55

Difference in delivery mm3/st. 3.5

Basic *

Injection timing adjustment_02

Pump speed r/min 1380 1380 1380

Average injection quantity mm3/st. 16.2 13.2 19.2

Injection timing adjustment_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 55 53 57

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 55 54 56

Injection timing adjustment_05

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 48.8 46.8 50.8

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 53.6 53.1 54.1

Difference in delivery mm3/st. 3.5

Basic *

Remarks
For Japan

Injection timing adjustment_07

Pump speed r/min 1380 1380 1380

Average injection quantity mm3/st. 15.8 12.8 18.8

Remarks
For Japan

Injection timing adjustment_08

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 53.6 51.6 55.6

Remarks
For Japan

Injection timing adjustment_09

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 53.6 52.6 54.6

Remarks
For Japan

Injection timing adjustment_10

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 47.6 45.6 49.6

Remarks
For Japan

Injection quantity adjustment

Pump speed r/min 1380 1380 1380

Average injection quantity mm3/st. 16.2 14.2 18.2

Basic *

Injection quantity adjustment_02

Pump speed r/min 1430 1430 1430

Average injection quantity mm3/st. 6.2

Injection quantity adjustment_03

Pump speed r/min 1380 1380 1380

Average injection quantity mm3/st. 15.8 12.8 18.8

Basic *

Remarks
For Japan

Injection quantity adjustment_04

Pump speed r/min 1430 1430 1430

Average injection quantity mm3/st. 6

Remarks
For Japan

Governor adjustment

Pump speed r/min 315 315 315

Average injection quantity mm3/st. 13.1 11.1 15.1

Difference in delivery mm3/st. 2.5

Basic *

Governor adjustment_02

Pump speed r/min 315 315 315

Average injection quantity mm3/st. 13.1 11.1 15.1

Governor adjustment_03

Pump speed r/min 620

Average injection quantity mm3/st. 0 0 0

Governor adjustment_04

Pump speed r/min 315 315 315

Average injection quantity mm3/st. 12.8 10.8 14.8

Difference in delivery mm3/st. 2.5

Basic *

Remarks
For Japan

Governor adjustment_05

Pump speed r/min 315 315 315

Average injection quantity mm3/st. 12.8 10.8 14.8

Remarks
For Japan

Governor adjustment_06

Pump speed r/min 620

Average injection quantity mm3/st. 0 0 0

Remarks
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

Speed control lever angle

Pump speed r/min 315 315 315

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

Speed control lever angle_02

Pump speed r/min 315 315 315

Average injection quantity mm3/st. 0 0 0

Remarks
For Japan: Magnet OFF

0000000901

Pump speed r/min 1000 1000 1000

Overflow quantity cm3/min 450 318 582

_02

Pump speed r/min 1000 1000 1000

Overflow quantity cm3/min 450 318 582

Remarks
For Japan

Stop lever angle

Pump speed r/min 1000 1000 1000

Pressure kPa 431.5 402 461

Pressure kgf/cm2 4.4 4.1 4.7

Basic *

Stop lever angle_02

Pump speed r/min 500 500 500

Pressure kPa 264.5 235 294

Pressure kgf/cm2 2.7 2.4 3

Stop lever angle_03

Pump speed r/min 1000 1000 1000

Pressure kPa 431.5 402 461

Pressure kgf/cm2 4.4 4.1 4.7

Stop lever angle_04

Pump speed r/min 1250 1250 1250

Pressure kPa 510 481 539

Pressure kgf/cm2 5.2 4.9 5.5

Stop lever angle_05

Pump speed r/min 1000 1000 1000

Pressure kPa 421.5 392 451

Pressure kgf/cm2 4.3 4 4.6

Basic *

Remarks
For Japan

Stop lever angle_06

Pump speed r/min 500 500 500

Pressure kPa 255 226 284

Pressure kgf/cm2 2.6 2.3 2.9

Remarks
For Japan

Stop lever angle_07

Pump speed r/min 1000 1000 1000

Pressure kPa 421.5 392 451

Pressure kgf/cm2 4.3 4 4.6

Remarks
For Japan

Stop lever angle_08

Pump speed r/min 1250 1250 1250

Pressure kPa 500.5 471 530

Pressure kgf/cm2 5.1 4.8 5.4

Remarks
For Japan

0000001101

Pump speed r/min 1000 1000 1000

Timer stroke mm 2.3 2.1 2.5

Basic *

_02

Pump speed r/min 1000 1000 1000

Timer stroke mm 2.3 2 2.6

_03

Pump speed r/min 1250 1250 1250

Timer stroke mm 3.8 3.2 4.4

_04

Pump speed r/min 1000 1000 1000

Timer stroke mm 2.2 2 2.4

Basic *

Remarks
For Japan

_05

Pump speed r/min 1000 1000 1000

Timer stroke mm 2.2 1.9 2.5

Remarks
For Japan

_06

Pump speed r/min 1250 1250 1250

Timer stroke mm 3.7 3.1 4.3

Remarks
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 1.8 1.7 1.9

Pre-stroke mm 0.2 0.18 0.22

Control lever angle alpha deg. 24 19 29

Control lever angle beta deg. 44 39 49

Information:

21Apr2010
U-136
A-108
D-119
O-126
TT-9
TM-8
TA-5
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 248-1079, 250-1305, 250-1368, 266-4387, AND 280-0681 FUEL INJECTORS (FOR 3508C, 3512C, AND 3516C ENGINES) FROM DEALER PARTS STOCK
7750 PI70341
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the 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
31Jul2010
PROBLEM
Certain 248-1079, 250-1305, 250-1368, 266-4387, and 280-0681 Fuel Injectors installed in certain 3512C and 3516C engine applications may experience internal body cracks. This condition may result in fuel to oil dilution.
ACTION REQUIRED
Refer to Image1 for Injector Part Numbers and Serial Number Range of affected parts. Refer to Image2 for example of part number (A) and injector serial number identification (B).
Inspect all injector part numbers listed in Image1 to identify if they are within the Serial Number range 1134640 - 1234085.
- If the injector part number listed in Image1 has a serial number that is included in the serial number range 1134640 - 1234085, remove the injector from dealer parts stock.
- If the injector part number listed in Image1 has a serial number that is NOT included in the serial number range 1134640 - 1234085, return the injector to the original packaging, mark the package to indicate the injector has been inspected according to this program (PI7#### / REBE6038), and return the injector to dealer parts stock.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
A Send-It-Back Parts Return Request will be generated when the claim is submitted with this program (PI7####) as the part causing failure.