104745-0140 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047450140

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104745-0140 1047450140

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Cross reference number

ZEXEL 104745-0140 1047450140

Zexel num

Bosch num

Firm num

Name

104745-0140

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)
Left L

Injection timing adjustment

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 56.8 56.3 57.3

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 51.5 48.5 54.5

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 56.8 55.8 57.8

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2000 2000 2000

Average injection quantity mm3/st. 56.2 52.7 59.7

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2450 2450 2450

Average injection quantity mm3/st. 22.9 19.9 25.9

Difference in delivery mm3/st. 4.5

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. 22.9 12.9 32.9

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 10.8 9.8 11.8

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. 10.8 9.3 12.3

Difference in delivery mm3/st. 2.2

Basic *

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

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

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

0000000901

Pump speed r/min 1250 1250 1250

Overflow quantity cm3/min 420 290 550

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Pressure kPa 559 530 588

Pressure kgf/cm2 5.7 5.4 6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Pressure kPa 559 520 598

Pressure kgf/cm2 5.7 5.3 6.1

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke mm 6 5.8 6.2

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 500 500 500

Timer stroke mm 0.9 0.1 1.7

Oil temperature degC 48 46 50

_03

Pump speed r/min 1250 1250 1250

Timer stroke mm 6 5.6 6.4

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1750 1750 1750

Timer stroke mm 8.9 8.1 9.7

Oil temperature degC 50 48 52

_05

Pump speed r/min 2100 2100 2100

Timer stroke mm 9.8 8.8 10.6

Oil temperature degC 52 50 54

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. 45 44.5 45.5

Timer stroke TA mm 5.3 5.3 5.3

Timer stroke variation dT mm 0.7 0.5 0.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 45 44 46

Timer stroke TA mm 5.3 5.3 5.3

Timer stroke variation dT mm 0.7 0.3 1.1

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 38 36.5 39.5

Timer stroke TA mm 4.7 4.7 4.7

Timer stroke variation dT mm 1.3 0.7 1.9

Oil temperature degC 50 48 52

0000001501

Pump speed r/min 1250 1250 1250

Height m 1560 1560 1560

Atmospheric pressure difference kPa -16.7 -16.7 -16.7

Atmospheric pressure difference mmHg -125 -125 -125

Average injection quantity mm3/st. 53 52.5 53.5

Decrease qty mm3/st. 3.8 3.8 3.8

Decrease rate % 7 7 7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Atmospheric pressure difference kPa -5.9 -5.9 -5.9

Atmospheric pressure difference mmHg -44 -69 -19

Average injection quantity mm3/st. 56.8 53.3 57.8

Decrease rate % 0 0 0

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Atmospheric pressure difference kPa -16.7 -16.7 -16.7

Atmospheric pressure difference mmHg -125 -125 -125

Average injection quantity mm3/st. 53 52 54

Decrease rate % 7 7 7

Basic *

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
----------

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0000001901 WIRE

Confirmation of the wire length: Accelerator wire: Idle-full stroke: L1 Adjustment of the double stage actuator: (1)Apply negative pressure P1 {P2} to the actuator through the negative pressure inlet port (A). (2)In condition (1), adjust using screw (C) so that control lever (B)'s position is a [ie, the distance from idle switch (E) is L2], then fix using nut (D). T:Tightening torque b:Alpha
----------
L1=34.1+3.5-5.5mm L2=5.1+-0.5mm a=9deg P1=-66.6kPa P2=-500mmHg T=6~9N-m(0.6~0.9kgf-m)
----------
a=9deg b=12.5+-4deg L2=5.1+-0.5mm

0000002001

Adjustment of the dash pot 1. Maintain the control lever (A) position at a (distance L from idle screw [D]) 2. In this condition of item 1., adjust the position of dashpot (B) so that the end of dashpot (B) contacts the control lever (A). Then, fix using bolt (C). Tightening torque is T. D:Dash pot contact position
----------
L=8.1-0.3mm T=6~9N-m(0.6~0.9Kgf-m) a=14.1deg-0.5deg
----------
L=8.1-0.3mm a=14.1deg-0.5deg b=12.5deg+-4deg

Information:

PARTS NEEDED
Qty
Part Number Description
2 5P4115 WASHER-HARD
2 6S8620 CLAMP-HOSE
4 8T4121 WASHER-HARD
2 8T4171 BOLT-HEX HEAD
2 8T4195 BOLT-HEX HEAD
1 3550632 CONNECTOR-SPL
1 4609257 INJECTOR AS-DEF
1 4719926 TANK AS-ALUMINUM
1 4719927 PLATE AS
2 4719928 PLATE AS
9 4721116 HOSE-BULK (9cm)
1 5218238 SFWR GP-A1000
1 BULK_COOLANT COOLANT - See Action Required
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
1. Replace the DEF Injector, As per the Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install". Please ensure that the coolant drained from the system is stored in a suitable storage container and not refilled until the end of the following procedure.
2. Position bracket assembly 471-9927 onto the CEM. Ensure that the bracket is correctly orientated. As per Image 1
3. Position the two 471-9928 plates onto the CEM and install 8T-4195 bolts with the 8T-4121 washers. As per Image 2
4. Position coolant tank 471-9926 onto bracket. Install bolts 8T-4171 with 5P-4115 washer. Tighten to 9 Nm. As per Image 1
5. Remove coolant supply hose 349-6234 from DEF injector and connect to tank 471-9926 inlet using existing clamp. As per Image 1
6. Connect hose assembly 472-1116 (9cm) to tank 471-9926 and the DEF injector. Secure with 2 off 6S?8620 clamps, As per Image 1
7. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, ?Cooling System Coolant - Change? for the correct procedure. If required, top up the coolant system.
8. Flash the engine ECM with the software or latest available in SIS Web.
For flash programming the engine ECM, refer to Troubleshooting, "Flash Programming".
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.