104740-9682 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047409682

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-9682 1047409682

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Cross reference number

ZEXEL 104740-9682 1047409682

Zexel num

Bosch num

Firm num

Name

104740-9682

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

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

(Solenoid timer adjustment condition) OFF

Injection timing adjustment

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 52.2 51.7 52.7

Difference in delivery mm3/st. 3

Basic *

Injection timing adjustment_02

Pump speed r/min 2550 2550 2550

Average injection quantity mm3/st. 10.1 5.6 14.6

Injection timing adjustment_03

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 33 30.5 35.5

Injection timing adjustment_04

Pump speed r/min 2150 2150 2150

Average injection quantity mm3/st. 42.9 40.8 45

Injection timing adjustment_05

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 52.2 51.2 53.2

Injection timing adjustment_06

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 52.8 50.8 54.8

Injection quantity adjustment

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 33 31 35

Basic *

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 5

Governor adjustment

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 7.3 5.3 9.3

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 7.3 5.3 9.3

Governor adjustment_03

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 3

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 62.5 45 80

Basic *

Speed control lever angle

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1100 1100 1100

Overflow quantity cm3/min 390 258 522

_02

Pump speed r/min 1100 1100 1100

Overflow quantity cm3/min 489 360 618

Remarks
Without an O-ring

Stop lever angle

Pump speed r/min 750 750 750

Pressure with S/T ON kPa 402 363 441

Pressure with S/T ON kgf/cm2 4.1 3.7 4.5

Pressure with S/T OFF kPa 294.5 275 314

Pressure with S/T OFF kgf/cm2 3 2.8 3.2

Basic *

Stop lever angle_02

Pump speed r/min 750 750 750

Pressure with S/T ON kPa 402 363 441

Pressure with S/T ON kgf/cm2 4.1 3.7 4.5

Pressure with S/T OFF kPa 294.5 275 314

Pressure with S/T OFF kgf/cm2 3 2.8 3.2

Stop lever angle_03

Pump speed r/min 1100 1100 1100

Pressure with S/T OFF kPa 372.5 343 402

Pressure with S/T OFF kgf/cm2 3.8 3.5 4.1

Stop lever angle_04

Pump speed r/min 1700 1700 1700

Pressure with S/T OFF kPa 510 481 539

Pressure with S/T OFF kgf/cm2 5.2 4.9 5.5

Stop lever angle_05

Pump speed r/min 2150 2150 2150

Pressure with S/T OFF kPa 598.5 569 628

Pressure with S/T OFF kgf/cm2 6.1 5.8 6.4

0000001101

Pump speed r/min 750 750 750

Timer stroke with S/T ON mm 2.8 2.4 3.2

Timer stroke with S/T OFF mm 1.2 1 1.4

Basic *

_02

Pump speed r/min 750 750 750

Timer stroke with S/T ON mm 2.8 2.3 3.3

Timer stroke with S/T OFF mm 1.2 0.9 1.5

_03

Pump speed r/min 1100 1100 1100

Timer stroke with S/T OFF mm 2.5 1.9 3.1

_04

Pump speed r/min 1700 1700 1700

Timer stroke with S/T OFF mm 4.9 4.2 5.6

_05

Pump speed r/min 2550 2550 2550

Timer stroke with S/T OFF mm 7.3 6.8 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 0.9 0.8 1

Control lever angle alpha deg. 55.5 51.5 59.5

Control lever angle beta deg. 36 31 41

Test data Ex:

0000001801 CONTROL LEVER ANGLE

Control lever angle measurement 1. Measure dimension Ya between the end of the lever and the flange face B. 2. Measure the lever angle from the R (plate) pin hole. (A) Lever angle measurement position
----------
Ya=8.4~12.2mm R=53mm
----------
Ya=8.4~12.2mm R=53mm Alpha=51.5~59.5deg Beta=31~41deg

0000001901 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Measure the injection quantity with the control lever a from the idle position (equal to shim thickness L1) at pump speed N5. Install the potentiometer so that injection quantity and output voltage correspond as shown in the graph. J = formula A = shim thickness C = control lever angle E = adjusting point Vi = applied voltage V = potentiometer voltage X = injection quantity Q Y = voltage (V) C2 = idle C3 = full speed F = potentiometer circuit diagram G = output N = pump speed Q = injection quantity 1 = black 2 = blue yellow 3 = blue red
----------
N5=750r/min a=9.0deg L1=6.0mm
----------
N1=750r/min N2=-r/min N3=-r/min N4=-r/min V1=4.0V V2=-V V3=-V V4=-V Q1=17.8+-1.8cm3/1,000st Q2=-cm3/1,000st Q3=-cm3/1,000st Q4=-cm3/1,000st C1=(9.0)deg C2=- C3=- C4=- A1=(6.0)mm A2=- A3=- A4=- J=V+-0.03=0.045X+3.197

Information:

Illustration 1 g00656709
(1) Error code (2) Activity on CAT Data Link (3) First digit of error code (4) The CCM is transmitting on RS 232C. (5) Second digit of error code (6) The CCM is receiving data on the RS 232C.The values E, 0, and 0 indicate an error code of 00. The code E00 means that no faults are present, and the CCM is in normal operating mode. The complete list of error codes are in the Operation and Maintenance Manual, "Troubleshooting" section. The periods on the display will flash when information is transmitted on the CAT Data Link. The periods on the display will flash when information is transmitted on the RS-232C port. No period indicates that no activity is taking place.Note: Units with the part number 117-6170 Customer Communication Module will display the faults that have been logged. Each fault will be displayed for 2 seconds in 60 second intervals. This flashing fault log will not appear for any other version of CCM. The fault log can be cleared by using the PC software for the CCM.CCM Power Up Display
The CCM display will perform a lamp test (8.8.8.). The parameters for communication protocol (n81 9600 E00) will be displayed next. An example of the power up sequence is given below:
Table 1
8.8.8. n81 9600 E00
8.8.8. All of the segments are turned on for a two second lamp test.
n81
n
8
1 No parity (default value)
Eight data bits (default value)
One stop bit (default value)
9600 Rate of Communication (default value)
E00 Error Code
No faults are present. The values for communication can be changed by using a host device or by using the PC software for the CCM. Refer to "Caterpillar CCM PC For Windows: Getting Started Manual". The values for communication must match the values for the modems (if used) and the values for the host device.