104741-7083 ZEXEL 9 460 613 892 BOSCH INJECTION-PUMP ASSEMBLY 9460613892 1047417083

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 613 892 9460613892

ZEXEL 104741-7083 1047417083

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Cross reference number

BOSCH 9 460 613 892 9460613892

ZEXEL 104741-7083 1047417083

Zexel num

Bosch num

Firm num

Name

104741-7083
104741-7084

9 460 613 892

INJECTION-PUMP ASSEMBLY
4D95L * K

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 1000 1000 1000

Average injection quantity mm3/st. 67 66.5 67.5

Difference in delivery mm3/st. 5.5

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 50 46.5 53.5

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 65 62 68

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 67 66 68

Difference in delivery mm3/st. 5.5

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 65.9 63.4 68.4

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 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. 83.5 78.5 88.5

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 83.5 78.5 88.5

Oil temperature degC 48 46 50

Remarks
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

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=6~9Nm(0.6~0.9kgfm)

Information:

04Feb2016
U-58
A-46
D-55
O-52
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 398-1498 AND 463-1678 FUEL INJECTION PUMPS FROM DEALER PARTS STOCK
7750 PI70604
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
The information supplied in this service letter may not be valid after the termination date of this program.Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
TERMINATION DATE
31May2016
PROBLEM
The existing 398-1498 and 463-1678 Fuel Injection Pumps can fail. Fuel Injection Pumps up to and inclusive of component serial number 06369GJG, are suspect.
ACTION REQUIRED
Inspect all 398-1498 and 463-1678 Fuel Injection Pumps in dealer parts stock. Review the component serial number on each 398-1498 and 463-1678 Fuel Injection Pump. The Fuel Injection Pump component serial number can be located on the Fuel Injection Pump data plate, affixed to the side of the Fuel Injection Pump body.
The Fuel Injection Pump component serial number is alphanumeric, Refer to Image 1 for explanation on component serial number translation. In the given example the date code would translate to the following - 6369th pump built in July 2015.
NOTE - The build facility is not applicable in determining if the Fuel Injection Pump is suspect or not.
Refer to Image 2 for the build month and build year translation table.
Please action according to the following build month and build year color code -
Red = Remove from dealer part stock
Orange = Check Fuel Injection Pump Serial Number (06369 and below = Remove from dealer part stock / 06370 and Up = Return to dealer part stock).
Green = OK, Return to dealer part stock.
- If the Fuel Injection Pump is removed from dealer parts stock. Refer to the Service Claim Allowances and Parts Disposition.
- If the Fuel Injection Pump is returned to dealer parts stock, mark the box as inspected.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all Fuel Injection Pumps removed from dealer parts stock. Include the date code (e.g. 06369GJG) in the claim story for each Fuel Injection Pump removed from dealer parts stock.
PARTS DISPOSITION
NACD:
Hold all 398-1498 and 463-1678 Fuel Injection Pumps removed from dealer parts stock for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing