Information injection-pump assembly
ZEXEL
104745-0040
1047450040
Rating:
Cross reference number
ZEXEL
104745-0040
1047450040
Zexel num
Bosch num
Firm num
Name
104745-0040
INJECTION-PUMP ASSEMBLY
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)
Left L
Left L
Injection timing adjustment
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
48.7
48.2
49.2
Difference in delivery
mm3/st.
4
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
44.8
41.8
47.8
Oil temperature
degC
48
46
50
Injection timing adjustment_03
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
48.7
47.7
49.7
Difference in delivery
mm3/st.
4.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
2100
2100
2100
Average injection quantity
mm3/st.
44.3
40.8
47.8
Oil temperature
degC
52
50
54
Injection quantity adjustment
Pump speed
r/min
2450
2450
2450
Average injection quantity
mm3/st.
15.7
12.7
18.7
Difference in delivery
mm3/st.
5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_02
Pump speed
r/min
2700
2700
2700
Average injection quantity
mm3/st.
8
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2450
2450
2450
Average injection quantity
mm3/st.
15.7
5.7
25.7
Difference in delivery
mm3/st.
5.5
Basic
*
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
9
8
10
Difference in delivery
mm3/st.
1.7
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
9
7.5
10.5
Difference in delivery
mm3/st.
2.2
Basic
*
Oil temperature
degC
48
46
50
Boost compensator adjustment
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
17
15
19
Difference in delivery
mm3/st.
3
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
70
55
90
Basic
*
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
70
50
90
Oil temperature
degC
48
46
50
Remarks
Full
Full
Speed control lever angle
Pump speed
r/min
360
360
360
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
1250
1250
1250
Overflow quantity with S/T ON
cm3/min
420
290
550
Overflow quantity with S/T OFF
cm3/min
460
330
590
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
1250
1250
1250
Pressure with S/T ON
kPa
569
530
608
Pressure with S/T ON
kgf/cm2
5.8
5.4
6.2
Pressure with S/T OFF
kPa
471
442
500
Pressure with S/T OFF
kgf/cm2
4.8
4.5
5.1
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
Stop lever angle_02
Pump speed
r/min
1250
1250
1250
Pressure with S/T OFF
kPa
471
432
510
Pressure with S/T OFF
kgf/cm2
4.8
4.4
5.2
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
0000001101
Pump speed
r/min
1250
1250
1250
Timer stroke with S/T ON
mm
5.7
5.3
6.1
Timer stroke with S/T OFF
mm
4.1
3.9
4.3
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_02
Pump speed
r/min
500
500
500
Timer stroke with S/T ON
mm
1.8
0.8
2.8
Oil temperature
degC
48
46
50
_03
Pump speed
r/min
1250
1250
1250
Timer stroke with S/T ON
mm
5.7
5.1
6.3
Timer stroke with S/T OFF
mm
4.1
3.7
4.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_04
Pump speed
r/min
2000
2000
2000
Timer stroke with S/T ON
mm
9.2
8.2
10
Timer stroke with S/T OFF
mm
7.6
7
8.2
Oil temperature
degC
50
48
52
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001401
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
35.6
35.1
36.1
Timer stroke TA
mm
3.8
3.8
3.8
Timer stroke variation dT
mm
0.3
0.1
0.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_02
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
35.6
34.6
36.6
Timer stroke variation dT
mm
0.3
-0.1
0.7
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_03
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
22.1
20.6
23.6
Timer stroke variation dT
mm
1
0.5
1.5
Oil temperature
degC
50
48
52
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
6.01
5.91
6.11
MS dimension
mm
0.9
0.8
1
Pre-stroke
mm
0.03
0.01
0.05
Control lever angle alpha
deg.
12.5
8.5
16.5
Control lever angle beta
deg.
40
37
43
Test data Ex:
0000001801 CONTROL STANDARD AT IDLING
Standards for idle difference in delivery control
After idle adjustment, measure the idle injection quantities of (A) to (D).
Install the colored rings to the delivery valve holders (A) to (D) in accordance with the table.
(A): A cylinder (B) :B cylinder (C) : C cylinder (D): D cylinder
(E): Collar ring
(F): (A) >= (C)
(G): (C) > (A)
(H): (A) - (C) or (C) - (A)
(I): 0.2, 0.1(mm3/st)
(J): (B) - (D) or (D) - (B)
(K): Ring color
(L): At least 0.6 mm3/st
(M): 0.3, 0.4, 0.5 (mm3/st)
(N): 0.2, 0.1, 0.0 (mm3/st)
(O): (B) >= (D)
(P): (D) > (B)
(T): Yellow
(U): White
(V): Red
----------
----------
----------
----------
0000001901 POTENTIOMETER ADJUSTMENT
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 to contact the dummy bolt. Adjust the potentiometer so that the output voltage is V1.
3. Remove the dummy bolt after the completion of adjustment.
Move the control lever and confirm that the potentiometer output voltage is within the above-mentioned standards.
N:Pump speed
Q:Injection quantity
V:Output voltage
C:Position of the control lever
C1:Idle
C2:Full
A:Adjusting point
B:Checking point
P:Boost pressure
Vi:Applied voltage
----------
N1=1500(r/min) Vi=10(V) Q1=15.2+-1.0(cm3/1,000st) V1=4.97+-0.03(V)
----------
N1=1500r/min Vi=10V Q1=15.2+-1.0cm3/1,000st V1=4.97+-0.03V V2=1.73+-0.70V V3=8.40+-0.53V a=18.0deg b=0deg c=40.0+-3.0deg P1=0kPa P2=0mmHg
----------
N1=1500(r/min) Vi=10(V) Q1=15.2+-1.0(cm3/1,000st) V1=4.97+-0.03(V)
----------
N1=1500r/min Vi=10V Q1=15.2+-1.0cm3/1,000st V1=4.97+-0.03V V2=1.73+-0.70V V3=8.40+-0.53V a=18.0deg b=0deg c=40.0+-3.0deg P1=0kPa P2=0mmHg
0000002001 WIRE
(1)Wire length confirmation
Accelerator wire: Idle-full stroke: L1 mm
(2)Idle switch confirmation
Confirm that the switch is ON in the idle lever position.
(3)2 stage lever adjustment
1. Apply negative pressure P1 kPa {P2 mmHg} to the negative pressure suction inlet.
2. Under the conditions in 1, adjust with the screw (C) so that the position of the control lever (B) becomes angle a [gap L2 from the idle screw (E)] and fix the nut (D).
T:Tightening torque
----------
L1=34.1+-3.5mm L2=4.6+-0.5mm P1=-66.0kPa P2=-500mmHg a=7.6deg T=6~9N-m(0.6~0.9Kgf-m)
----------
a=7.6deg b=12.5+-4deg L2=4.6mm
----------
L1=34.1+-3.5mm L2=4.6+-0.5mm P1=-66.0kPa P2=-500mmHg a=7.6deg T=6~9N-m(0.6~0.9Kgf-m)
----------
a=7.6deg b=12.5+-4deg L2=4.6mm
Information:
03May2017
U-247
A-163
D-194
O-200
TM-3
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING CERTAIN REMAN FUEL INJECTORS IN DEALER PARTS STOCK
7750 PI70664
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
31Aug2017
PROBLEM
Certain Reman fuel injectors were labeled with the same "2755" trim code from January 9, 2017 through April 18, 2017. The injector serial numbers of suspect injectors are 1825569 through 1880788. The trim code may or may not be correct. Image 1 shows a suspect trim code.
Parts from part distribution centers have been inspected and the boxes have been marked with a large green dot to indicate the injector has been inspected, marked correctly, or the trim code is correct. Refer to Image 2.
ACTION REQUIRED
Inspect the following Reman injectors in dealer parts stock:
20R0848
20R0849
20R0850
20R0863
20R0864
20R1264
20R1265
20R1266
20R1268
20R1269
20R1270
20R1271
20R1272
20R1273
20R1274
20R1275
20R1276
20R1277
20R1278
20R1279
20R1280
20R1281
20R1282
20R1283
20R2296
20R3247
20R3477
20R3479
20R3480
20R3483
Inspect the date code on the box.
If the date code on the box is not January 9, 2017 through April 18, 2017, then mark the box as inspected per this program and place the part back in dealer parts stock.
If the date code on the box is January 9, 2017 through April 18, 2017, then inspect the injector trim code.
If the trim code is not "2755", then mark the box as inspected per this program and place the part back in dealer parts stock.
If the trim code is "2755", then inspect the injector serial number using the following inspection and rework the procedure:
Use the following web address and download the spreadsheet file:
https://cat.box.com/s/4fwh9nz0lwguh8vomifxj2rapqjc27e9
Use the downloaded file. Type in the injector serial number to check the trim code. The spreadsheet will return whether the trim code is OK to use, or rework and mark the injector with the correct trim code.
Note: Some injector serial numbers will show "2755" as the correct trim code.
If the trim code is correct (acceptable trim code), record the injector serial number, then mark the box as inspected per this program and place the part back in dealer parts stock.
If the trim code is not correct (rework), the injector must be relabeled. Use an engraving tool to cross out the original trim code and write the correct trim code as shown in Image 3. Record the injector serial number and the updated/corrected trim code, then mark the box as reworked per this program and place the part back in dealer parts stock.
Image1
Image2
Image3
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts inspected and reworked from dealer parts stock.
Have questions with 104745-0040?
Group cross 104745-0040 ZEXEL
104745-0040
INJECTION-PUMP ASSEMBLY