104741-3840 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047413840

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-3840 1047413840

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Cross reference number

ZEXEL 104741-3840 1047413840

Zexel num

Bosch num

Firm num

Name

104741-3840

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 with S/T ON cm3/min 740 610 870

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1500 1500 1500

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T OFF kPa 500 480 520

Pressure with S/T OFF kgf/cm2 5.1 4.9 5.3

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1500 1500 1500

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T OFF mm 3.4 3.2 3.6

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T ON mm 3.9 3.2 4.6

Timer stroke with S/T OFF mm 1

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T OFF mm 2 1.3 2.7

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 with S/T ON mm 6.8 6.1 7.5

Timer stroke with S/T OFF mm 3.4 3 3.8

Basic *

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 with S/T OFF mm 6.3 5.6 7

Oil temperature degC 50 48 52

_06

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T ON mm 8.6 8.1 9

Timer stroke with S/T OFF mm 8 7.3 8.7

Oil temperature degC 52 50 54

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+-1.0mm3/st
----------
N1=750r/min V1=4.16+-0.03V V2=2.16+-0.52V V3=9.02+-0.72V Q1=34.7+-1.0mm3/st Vi=10V

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the advance angle of the timer (1)Determine the timer advance angle using the following graph. (2)(1) Adjust with the screw (A) so that the timer advance angle determined in the item (1) is obtained. X:Temperature t (deg C) Y:Timer stroke TA (mm) (B): Timer stroke TA (mm):
----------

----------
(B)=TA=-0.04t+1.2(0<=t<=30)

0000002001 W-FICD LEVER ADJUSTMENT

2. Adjustment of the W-FICD (1)Insert a block gauge L1 determined from the graph below between the control lever (D) and the idle set screw (C). (2)Tighten the nut (F) at the position where the W-FICD lever (E) the control lever (D) contact. T2T2 (3)After adjusting the W-FICD lever (E), confirm that the timer stroke is the value adjusted in item 1. Then, remove the shim. Y = control lever position X = temperature G = control lever position: (mm)
----------
L1=L+-0.3 mm T2=6~9 N-m{0.6~0.9 kgf-m}
----------
L1=L+-0.3 mm SW2=SW10 T2=6~9 N-m{0.6~0.9 kgf-m} SW1=SW8 T1=3.4~4.9 N-m{0.35~0.5 kgf-m}

Information:

REM05-08
CAT® Reman
February 2005 APPEARANCE CHANGE TO CAT® REMAN DIFN NOZZLES Announcement The Caterpillar Remanufactured Products Group announces an appearance change on selected Cat Reman DIFN nozzles effective 02/04/05. In order to improve the salvage of DIFN nozzles, Cat Reman will begin using bodies for a third life on select DIFN nozzels. The current process allows for only one use. Effective on 02/04/05 they will begin machining the nozzle bodies to allow for a new tip to be pressed in. These nozzles will have the appearance of having a longer tip and shorter body. See pictures below. This change will not alter fit or performance in any way. Part Numbers Impacted
The table below lists part numbers impacted by this change.
Features and Benefits
Cat Remanufactured fuel nozzles offer excellent value to customers. Customers who want fast repair turn-around, superior quality and reliability, and lower repair costs will benefit from the use of these Remanufactured fuel nozzles. Cat Remanufactured fuel nozzles provide immediate, off-the-shelf availability at a fraction of the new price.
Features Benefits
All critical engineering changes and updates included
Improved reliability and performance
Worldwide availability through Caterpillar® parts distribution system
Customer access regardless of location
Backed by Cat warranty
Consistent support
Core Acceptance Core Acceptance Criteria for Caterpillar Remanufactured fuel nozzles is simple, visual, and requires no special tools. Consult your Core Acceptance Guide for complete details. Warranty Please consult the appropriate warranty statement for your area. Core Management Please refer to the Caterpillar core Management Information System (CMIS 2) Parts Information application describing all reman part/CAF and related information. Also refer to other CMIS 2 inquiry applications such as Customer Profiles, Inspection Reason Codes, Inspection Line Inquiry, Add Charge Information, Entitlement Activity, Entitlement Inquiry, CCR Inquiry, CCR Entry, Shipment Processing; Process Packaging Grief; and Reporting to properly manage core returns and monitor inspection performance. This information will be available to all dealers worldwide after your CMIS 2 conversion date. In the meantime, please continue to use the current CMIS Entitlement Parts Inquiry Screen describing the list of parts in a Core Acceptability Family (CAF) and related part number detail. For the latest updates of Reman Policies and Core Management (SELD0122), Core Management Systems & Operations Procedures (SELD0040), and Shipping Instructions (SELD00390, go to the Reman Dealer website https://reman.cat.com. If you have any questions regarding core return processing, feel free to call Corinth toll free at (800) 537-2928. For assistance with technical questions, call the Peoria Reman Customer Satisfaction Hot Line also toll free at (888) 88-REMAN or use our E-mail address--Reman_Help.
PELJ0505 CATERPILLAR® ?2005 Caterpillar