104740-9702 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047409702

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-9702 1047409702

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Cross reference number

ZEXEL 104740-9702 1047409702

Zexel num

Bosch num

Firm num

Name

104740-9702

INJECTION-PUMP ASSEMBLY
11CJ INJECTION PUMP ASSY VE4 VE

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 750 750 750

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 with S/T ON cm3/min 390 258 522

_02

Pump speed r/min 1100 1100 1100

Overflow quantity with S/T ON 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 ON kPa 480.5 441 520

Pressure with S/T ON kgf/cm2 4.9 4.5 5.3

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 ON kPa 618 579 657

Pressure with S/T ON kgf/cm2 6.3 5.9 6.7

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 ON mm 4.2 3.4 5

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 ON mm 6.5 5.7 7.3

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 In the following condition, change the installation position of the potentiometer to adjust the output voltage to within the specified values. Measure the injection quantity at control lever position a (shim thickness = approximately L mm) at N = N1 r/min, determine the voltage using the formula, and adjust the potentiometer. A:Performance standards C:Position of the control lever N:Pump speed Vo:Output voltage E:Conversion formula G:Idling H:Full speed K:Applied voltage X:Injection quantity (cm3/1,000st) Y:Voltage (V) R:At target value Q1cm3/1,000 st, set voltage at V3 (V). M:The switch voltage specification is the value when the full lever position is V6. B:Conversion point B1:ON-->OFF B2:OFF-->ON D:Lever opening (from idle)
----------
N1=750r/min a=8+-0.5deg L=5.3mm V3=-V V6=6V or more Q1=-cm3/1,000st
----------
J:V+-0.03=0.0672X+1.6031(V) K=10V V1=-V V2=-V V4=-V V5=-V D1=5.7+-3.5deg D2=20.2+-3.5deg

Information:

You should follow the instructions in Operations and Maintenance Manual, "Initialization for Direct Connection" before you connect by a modem. The user can verify proper operation of the CCM at the location. The user can also become familiar with the CCM. Make sure that the following equipment is available:
A personal computer with a terminal emulator software program. Examples of terminal emulators include Procomm, PC-VT, or Terminal under the Accessories window in Microsoft Windows. Refer to "Caterpillar CCM PC For Windows: Getting Started Manual" for specifications on the PC. The user is responsible for understanding the operation of the PC.
The proper RS-232C cables are required for the particular installation. An RS-232C cable must be temporarily connected from the PC to the Answering Modem. Refer to Operation and Maintenance Manual, "RS-232C Cable Requirements".
The two modems must support the Hayes AT command set. This is necessary for both the Answering Modem and the Originating Modem.
The CCM PC For Windows software is required. This software is available from Caterpillar.Note: Some personal computers will have an internal modem. The internal modem may be used as the Originating Modem. The internal modem must be compatible with the Answering Modem. Consult the instructions for the two modems.ProcedurePerform the following procedure in order to initialize communication with the CCM and the Answering Modem. The Originating Modem is set up later by the PC software.Note: In the following steps, the PC and the modems should be turned OFF before you change the cables on the serial ports. When power is reapplied, the modem must be powered up first.
The CCM should be installed with all of the wiring. Refer to the Operations and Maintenance Manual, "General Wiring Diagram" and "RS-232C Cable Requirements".
Determine the parameters for communication for the installation. The RS-232C default rate of communication (bits per second or bps) is 9600. The remaining default settings from the factory are no parity, 8 data bits, and 1 stop bit. These parameters will work well in most installations. Use the Operation and Maintenance Manual, "Communication Parameters - Identify" to determine the parameters of communication that are stored in the CCM.Note: The RS-232C serial port communication baud rate is often referred to as the DTE speed. The phone port communication rate is often referred to as the DCE speed.
Connect the RS-232C port of the Answering Modem directly to the RS-232C port of the PC. This connection is temporary. This connection is required to set up the Answering Modem.
Use the terminal emulator on the PC to set the parameters for communication for the RS-232C port. Use the same values that were chosen in step 2.
Several commands must be sent to the Answering Modem that set the parameters for communication to the proper values. The examples in Table 1 are Hayes AT commands. Actual command sets vary widely between modem manufacturers. Consult the manual for the modem. Save these parameters to the modem memory.
Table 1
Typical Answering Modem Setup Commands
Item Explanation Command Example Command