Information injection-pump assembly
ZEXEL
104740-9750
1047409750
Rating:
Cross reference number
ZEXEL
104740-9750
1047409750
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
1100
1100
1100
Average injection quantity
mm3/st.
44.3
43.8
44.8
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
43.2
41.2
45.2
Oil temperature
degC
50
48
52
Injection timing adjustment_03
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
44.3
43.3
45.3
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
2150
2150
2150
Average injection quantity
mm3/st.
37.8
35.7
39.9
Oil temperature
degC
52
50
54
Injection quantity adjustment
Pump speed
r/min
2500
2500
2500
Average injection quantity
mm3/st.
8.8
6.8
10.8
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_02
Pump speed
r/min
2700
2700
2700
Average injection quantity
mm3/st.
5
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2500
2500
2500
Average injection quantity
mm3/st.
8.8
5.3
12.3
Basic
*
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
6.5
4.5
8.5
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
6.5
4
9
Difference in delivery
mm3/st.
2.5
Basic
*
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60
45
80
Basic
*
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60
45
80
Oil temperature
degC
48
46
50
Speed control lever angle
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
0000000901
Pump speed
r/min
1100
1100
1100
Overflow quantity
cm3/min
390
260
520
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
1700
1700
1700
Pressure
kPa
579
550
608
Pressure
kgf/cm2
5.9
5.6
6.2
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_02
Pump speed
r/min
1700
1700
1700
Pressure
kPa
579
540
618
Pressure
kgf/cm2
5.9
5.5
6.3
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_03
Pump speed
r/min
2150
2150
2150
Pressure
kPa
677
638
716
Pressure
kgf/cm2
6.9
6.5
7.3
Oil temperature
degC
52
50
54
0000001101
Pump speed
r/min
1700
1700
1700
Timer stroke
mm
4.6
4.4
4.8
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
700
700
700
Timer stroke
mm
0.5
0.5
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1100
1100
1100
Timer stroke
mm
2.5
1.9
3.1
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
1700
1700
1700
Timer stroke
mm
4.6
4.2
5
Basic
*
Oil temperature
degC
50
48
52
_05
Pump speed
r/min
2500
2500
2500
Timer stroke
mm
7
6.5
7.4
Oil temperature
degC
55
52
58
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001501
Pump speed
r/min
1100
1100
1100
Height
m
2000
2000
2000
Atmospheric pressure difference
kPa
-21.9
-23.2
-20.6
Atmospheric pressure difference
mmHg
-164
-174
-154
Average injection quantity
mm3/st.
38.6
37.1
40.1
Decrease qty
mm3/st.
5.7
5.7
5.7
Decrease rate
%
12.9
12.9
12.9
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
1100
1100
1100
Height
m
0
0
0
Atmospheric pressure difference
kPa
0
0
0
Atmospheric pressure difference
mmHg
0
0
0
Average injection quantity
mm3/st.
44.3
43.3
45.3
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1100
1100
1100
Height
m
500
500
500
Atmospheric pressure difference
kPa
-5.9
-9.2
-2.6
Atmospheric pressure difference
mmHg
-44
-69
-19
Average injection quantity
mm3/st.
44.3
44.3
44.3
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
1100
1100
1100
Height
m
2000
2000
2000
Atmospheric pressure difference
kPa
-21.9
-23.2
-20.6
Atmospheric pressure difference
mmHg
-164
-174
-154
Average injection quantity
mm3/st.
38.6
36.6
40.6
Oil temperature
degC
50
48
52
_05
Pump speed
r/min
1100
1100
1100
Height
m
4000
4000
4000
Atmospheric pressure difference
kPa
-39.7
-41
-38.4
Atmospheric pressure difference
mmHg
-298
-308
-288
Average injection quantity
mm3/st.
30.2
30.2
30.2
Oil temperature
degC
50
48
52
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.75
5.65
5.85
MS dimension
mm
1
0.9
1.1
Control lever angle alpha
deg.
25
21
29
Control lever angle beta
deg.
36
31
41
Information:
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Caterpillar has discovered that when certain products equipped with the Caterpillar Regeneration System (CRS) are left idling for extended periods of time (greater than 1 hr) and ambient temps are lower than −15° C (5° F), certain conditions may be met which will disable the ability to regenerate the DPF. If the regeneration system cannot activate, the DPF will accumulate too much soot and must eventually be replaced.The issues Caterpillar has identified in extreme cold ambient conditions are the coolant temperature may become too cold for the regeneration system to activate. Also, the pressure lines which connect the DPF inlet section to the DPF intake pressure sensor may collect condensation and freeze. This freezing causes an E1154 (2) or 3609-18 Low DPF #1 Intake Pressure event code. The event code will disable the regeneration until the fault condition goes away.If you suspect low coolant temperature may be contributing to an inability to regenerate the DPF, review the product status report. The product status report is used for investigating the following fault code trend. If coolant temp is the only issue, you will likely see a combination of the following fault codes:
E995 (2) High DPF #1 Soot Loading or 3719-16 Particulate Trap #1 Soot Load Percent : High - moderate severity (2)
Indicates DPF soot load percent has reached 100 percent
E995(3) High DPF #1 soot loading or 3719-0 Particulate Trap #1 Soot Load Percent : High - most severe (3)
Indicates DPF soot load percent has reached 116 percent
E992(3) DPF Active Regeneration Inhibited Due to Temporary System Lockout or 3714-31 Particulate Trap Active Regeneration Inhibited Due to Temporary System Lockout
Indicates DPF soot load reached 116 percent and 10 minutes has passed since that point. Ability to perform automatic or manual regenerations is disabled. Caterpillar Electronic Technician (ET) regeneration is only type of regeneration allowed.
E991 (3) DPF Active Regeneration Inhibited Due to Permanent System Lockout or 3715-31 Particulate Trap Active Regeneration Inhibited Due to Permanent System Lockout
Indicates DPF soot load percent has reached 140 percent. All types of regeneration are disabled. DPF must be replaced as the amount of soot load will damage the DPF if ignited by regeneration process.If you suspect the pressure line for the DPF intake pressure has frozen, you will see a combination of fault codes. These codes will consist of the codes listed above with the addition of the following codes: E1154 (2) DPF #1 intake pressure low and 3609-18 DPF #1 Intake Pressure : Low - moderate severity (2).Solution
Caterpillar recommends the following when extended idling is likely to occur and ambient temperatures are less than −15° C (5° F):
Turn off machine before the end of shift. Before shutting down, perform a manual DPF regeneration and reduce soot load to 0 percent. The soot load must be above the 15 percent threshold needed to activate a manual DPF regeneration.If extended idling is
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Caterpillar has discovered that when certain products equipped with the Caterpillar Regeneration System (CRS) are left idling for extended periods of time (greater than 1 hr) and ambient temps are lower than −15° C (5° F), certain conditions may be met which will disable the ability to regenerate the DPF. If the regeneration system cannot activate, the DPF will accumulate too much soot and must eventually be replaced.The issues Caterpillar has identified in extreme cold ambient conditions are the coolant temperature may become too cold for the regeneration system to activate. Also, the pressure lines which connect the DPF inlet section to the DPF intake pressure sensor may collect condensation and freeze. This freezing causes an E1154 (2) or 3609-18 Low DPF #1 Intake Pressure event code. The event code will disable the regeneration until the fault condition goes away.If you suspect low coolant temperature may be contributing to an inability to regenerate the DPF, review the product status report. The product status report is used for investigating the following fault code trend. If coolant temp is the only issue, you will likely see a combination of the following fault codes:
E995 (2) High DPF #1 Soot Loading or 3719-16 Particulate Trap #1 Soot Load Percent : High - moderate severity (2)
Indicates DPF soot load percent has reached 100 percent
E995(3) High DPF #1 soot loading or 3719-0 Particulate Trap #1 Soot Load Percent : High - most severe (3)
Indicates DPF soot load percent has reached 116 percent
E992(3) DPF Active Regeneration Inhibited Due to Temporary System Lockout or 3714-31 Particulate Trap Active Regeneration Inhibited Due to Temporary System Lockout
Indicates DPF soot load reached 116 percent and 10 minutes has passed since that point. Ability to perform automatic or manual regenerations is disabled. Caterpillar Electronic Technician (ET) regeneration is only type of regeneration allowed.
E991 (3) DPF Active Regeneration Inhibited Due to Permanent System Lockout or 3715-31 Particulate Trap Active Regeneration Inhibited Due to Permanent System Lockout
Indicates DPF soot load percent has reached 140 percent. All types of regeneration are disabled. DPF must be replaced as the amount of soot load will damage the DPF if ignited by regeneration process.If you suspect the pressure line for the DPF intake pressure has frozen, you will see a combination of fault codes. These codes will consist of the codes listed above with the addition of the following codes: E1154 (2) DPF #1 intake pressure low and 3609-18 DPF #1 Intake Pressure : Low - moderate severity (2).Solution
Caterpillar recommends the following when extended idling is likely to occur and ambient temperatures are less than −15° C (5° F):
Turn off machine before the end of shift. Before shutting down, perform a manual DPF regeneration and reduce soot load to 0 percent. The soot load must be above the 15 percent threshold needed to activate a manual DPF regeneration.If extended idling is