104741-3810 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047413810

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-3810 1047413810

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Cross reference number

ZEXEL 104741-3810 1047413810

Zexel num

Bosch num

Firm num

Name

104741-3810

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

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 750 750 750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 57.1 56.6 57.6

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 750 750 750

Boost pressure kPa 46.7 45.4 48

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 73.8 73.3 74.3

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 84.4 83.9 84.9

Difference in delivery mm3/st. 6.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 57.1 56.1 58.1

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 750 750 750

Boost pressure kPa 46.7 45.4 48

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 73.8 72.8 74.8

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 84.4 83.4 85.4

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 71.8 67.8 75.8

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2475 2475 2475

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 26.4 23.4 29.4

Difference in delivery mm3/st. 8

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 3000 3000 3000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 8

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2475 2475 2475

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 26.4 21.4 31.4

Difference in delivery mm3/st. 8.5

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 18.9 16.9 20.9

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 18.9 16.4 21.4

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5

Oil temperature degC 50 48 52

Timer adjustment

Pump speed r/min 150 150 150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 78.1 58.1 98.1

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 150 150 150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 78.1 58.1 98.1

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Overflow quantity cm3/min 740 610 870

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 500 480 520

Pressure kgf/cm2 5.1 4.9 5.3

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 3.7 3.5 3.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 750 750 750

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 1.7 1.1 2.3

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 3.7 3.3 4.1

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 6.9 6.3 7.5

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 8.6 8.1 9

Oil temperature degC 50 48 52

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

BCS stroke mm 5.5 5.3 5.7

Control lever angle alpha deg. 59 55 63

Control lever angle beta deg. 41 36 46

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Adjusting method (service voltage Vi, dummy bolt): 1. Hold the dummy bolt against the control lever when N = N1 r/min, Q = Q1 mm3/st. Fix using the lock nut. 2. When adjusting the potentiometer, position the control lever against the dummy bolt and adjust the potentiometer so that the output voltage is V1 (V). 3. Remove the dummy bolt after the completion of adjustment. Confirm that the potentiometer output voltage is within the standards mentioned when the control lever is idling and in full-speed position. Vi:Applied voltage C:Position of the control lever N:Pump speed (r/min) V:Output voltage (V) Q:Injection quantity (mm3/st) A:Adjusting point B:Checking point C1:Idling C2:Full speed P1:Boost pressure P2:Boost pressure
----------
N1=750r/min V1=4.16+-0.03V Q1=34.7+-1.0cm3/1,000st
----------
N1=750(r/min) V1=4.16+-0.03(V) V2=2.16+-0.52(V) V3=9.02+-0.72(V) Q1=34.7+-1.0(mm3/st) Vi=10V

Information:

Operations that may cause product damage are identified by notice labels in this publication.
Introduction
This Tool Operating Manual contains two filter installation procedures. This first procedure is for installing a primary filter system. This is a coarse filter and will protect the transfer pump from contamination in the oil. The second procedure outlines installing a secondary filter which is designed to protect injection pumps from contaminated oil. Fuel injection pumps used on the 3208 Engine are one example of a fuel injection pump that requires the secondary filter installation.It will be the dealer choice as to which optional filter is installed on the test stand. Determine what type of filtering will be required most often, and install the appropriate type of filtering system. These filters can only be added to the 15 horsepower test stands.Secondary Filter
Nomenclature
Illustration 1. Nomenclature for Secondary Filter Installation. Refer to Chart A for item identification. Fabricated Parts
All the parts required for this installation can be ordered from Caterpillar Parts Distribution, except bracket (1). This must be manufactured by the bench owner, using the dimensions provided below.This bracket can be made from common SAE1018 steel. Weld the two pieces together.
Illustration 2. Filter Mounting Bracket. Refer to Chart B for dimensions. Installation
Assemble the Fuel Filter
1. Install 053-0088 Fitting (17) with 3J-1907 Seal (18) into the inlet port (left side) of the filter base. (This converts a number 6 STOP port to NPT). Install 5P-4455 Fitting (19) into fitting (17).2. Install 2R-6806 Fitting (15) with 3J-1907 Seal (16) into the outlet port (right side) of the filter base.3. Install 6N-4414 Cover (7) onto the filter base using 1P-0436 Gasket (8), 4B-3388/6V-2317 (9), and OS-1616/6V-8490 Bolt (10).4. Install 9S-4182 Plug (5) with 6V-5084 O-ring Seal (6) into the top of the filter base.5. Install the filter base assembly onto filter bracket (1),