Information injection-pump assembly
BOSCH
9 460 613 498
9460613498
ZEXEL
104741-7082
1047417082
Rating:
Cross reference number
BOSCH
9 460 613 498
9460613498
ZEXEL
104741-7082
1047417082
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
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
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
Right R
Injection timing adjustment
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
50
49.5
50.5
Difference in delivery
mm3/st.
4
Basic
*
Oil temperature
degC
48
46
50
Injection timing adjustment_02
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
50.6
47.1
54.1
Oil temperature
degC
48
46
50
Injection timing adjustment_03
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
50
49
51
Difference in delivery
mm3/st.
4
Basic
*
Oil temperature
degC
48
46
50
Injection timing adjustment_04
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
58.7
55.7
61.7
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
63.8
60.3
67.3
Oil temperature
degC
50
48
52
Injection quantity adjustment
Pump speed
r/min
1225
1225
1225
Average injection quantity
mm3/st.
12
8
16
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
50
48
52
Injection quantity adjustment_02
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
3
Oil temperature
degC
50
48
52
Injection quantity adjustment_03
Pump speed
r/min
1225
1225
1225
Average injection quantity
mm3/st.
12
7.5
16.5
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
50
48
52
Governor adjustment
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
8.7
6.7
10.7
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
3
Oil temperature
degC
48
46
50
Governor adjustment_03
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
8.7
6.2
11.2
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
77.6
72.6
82.6
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
77.6
72.6
82.6
Oil temperature
degC
48
46
50
Remarks
Full
Full
Speed control lever angle
Pump speed
r/min
400
400
400
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
340
210
470
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
1100
1100
1100
Pressure
kPa
324
304
344
Pressure
kgf/cm2
3.3
3.1
3.5
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_02
Pump speed
r/min
1100
1100
1100
Pressure
kPa
324
295
353
Pressure
kgf/cm2
3.3
3
3.6
Basic
*
Oil temperature
degC
50
48
52
0000001101
Pump speed
r/min
1100
1100
1100
Timer stroke
mm
0.9
0.7
1.1
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
1000
1000
1000
Timer stroke
mm
0.5
0
1
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1100
1100
1100
Timer stroke
mm
0.9
0.6
1.2
Basic
*
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
1200
1200
1200
Timer stroke
mm
1.2
0.7
1.7
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
2.8
2.7
2.9
KF dimension
mm
5
4.9
5.1
MS dimension
mm
1.8
1.7
1.9
Pre-stroke
mm
0.45
0.43
0.47
Control lever angle alpha
deg.
16
12
20
Control lever angle beta
deg.
32
27
37
Test data Ex:
0000001801 STARTING I/Q ADJUSTMENT
Starting Q decrease lever adjustment
Adjust using the screw (A) so that the standards are satisfied, then fix using the nut (B).
Screw (B) protrusion: L
(C) = Cap
(D) = Stop lever
----------
L=7.4~11.1mm
----------
L=7.4~11.1mm T=6~9N-m(0.6~0.9kgf-m)
----------
L=7.4~11.1mm
----------
L=7.4~11.1mm T=6~9N-m(0.6~0.9kgf-m)
Information:
ACTION REQUIRED
Before completing this Rework Procedure, please review the safety actions in the Operation and Maintenance Manual for your machine.
Choose one of the following actions:
Before Failure: If electronic unit fuel injectors have not failed, reflash the engine ECM with the new software. The new software offers enhanced protection to the fuel system if the fuel/water separator is not drained of water when the "Water Separator Full Indicator" is displayed.
After Failure: If electronic unit fuel injectors have failed, replace the injectors and reflash the engine ECM with the new software.
For detailed instructions on removing and installing the injectors, refer to UENR0633, Disassembly and Assembly, "Electronic Unit Injector - Remove" and "Electronic Unit Injector - Install".
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.0-hour job for Group 1
1 hour to update the software. An additional 3 hours is allowed to replace the injectors, after failure.
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.0-hour job for Group 2
1 hour to update the software. An additional 3 hours is allowed to replace the injectors, after failure.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.