104745-4030 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047454030

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104745-4030 1047454030

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Cross reference number

ZEXEL 104745-4030 1047454030

Zexel num

Bosch num

Firm num

Name

104745-4030

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 800 800 800

Boost pressure kPa 30.65 29.3 32

Boost pressure mmHg 230 220 240

Average injection quantity mm3/st. 54.9 54.4 55.4

Basic *

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1100 1100 1100

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 61.5 61 62

Difference in delivery mm3/st. 5

Basic *

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 2500 2500 2500

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 19.6 15.1 24.1

Injection timing adjustment_04

Pump speed r/min 2250 2250 2250

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 42.8 40.3 45.3

Injection timing adjustment_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 57.3 54.8 59.8

Injection timing adjustment_06

Pump speed r/min 1100 1100 1100

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 61.5 60.5 62.5

Injection timing adjustment_07

Pump speed r/min 1100 1100 1100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 45.3 42.8 47.8

Injection timing adjustment_08

Pump speed r/min 800 800 800

Boost pressure kPa 30.65 29.3 32

Boost pressure mmHg 230 220 240

Average injection quantity mm3/st. 54.9 53.9 55.9

Injection timing adjustment_09

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 48.5 45.5 51.5

Injection quantity adjustment

Pump speed r/min 2250 2250 2250

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 42.8 40.8 44.8

Basic *

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 5

Governor adjustment

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10 8 12

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 750 750 750

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

Governor adjustment_03

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10 7.5 12.5

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 77.5 60 95

Basic *

Speed control lever angle

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1100 1100 1100

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Overflow quantity with S/T ON cm3/min 390 258 522

Remarks
With an O-ring

_02

Pump speed r/min 1100 1100 1100

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Overflow quantity with S/T ON cm3/min 489 360 618

Remarks
Without an O-ring

Stop lever angle

Pump speed r/min 1100 1100 1100

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Pressure with S/T ON kPa 520 481 559

Pressure with S/T ON kgf/cm2 5.3 4.9 5.7

Pressure with S/T OFF kPa 451.5 422 481

Pressure with S/T OFF kgf/cm2 4.6 4.3 4.9

Basic *

Stop lever angle_02

Pump speed r/min 1100 1100 1100

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Pressure with S/T ON kPa 520 481 559

Pressure with S/T ON kgf/cm2 5.3 4.9 5.7

Pressure with S/T OFF kPa 451.5 422 481

Pressure with S/T OFF kgf/cm2 4.6 4.3 4.9

Stop lever angle_03

Pump speed r/min 1750 1750 1750

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Pressure with S/T ON kPa 686.5 647 726

Pressure with S/T ON kgf/cm2 7 6.6 7.4

Pressure with S/T OFF kPa 617.5 588 647

Pressure with S/T OFF kgf/cm2 6.3 6 6.6

Stop lever angle_04

Pump speed r/min 2150 2150 2150

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Pressure with S/T OFF kPa 715.5 686 745

Pressure with S/T OFF kgf/cm2 7.3 7 7.6

0000001101

Pump speed r/min 1100 1100 1100

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Timer stroke with S/T ON mm 6 5.6 6.4

Timer stroke with S/T OFF mm 4.8 4.6 5

Basic *

_02

Pump speed r/min 850 850 850

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Timer stroke with S/T OFF mm 3.6 3 4.2

_03

Pump speed r/min 1100 1100 1100

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Timer stroke with S/T ON mm 6 5.4 6.6

Timer stroke with S/T OFF mm 4.8 4.5 5.1

_04

Pump speed r/min 1750 1750 1750

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Timer stroke with S/T ON mm 9.1 8.5 9.7

Timer stroke with S/T OFF mm 7.9 7.3 8.5

_05

Pump speed r/min 2250 2250 2250

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Timer stroke with S/T OFF mm 9.7 9.2 10.2

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1100 1100 1100

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 36 35.5 36.5

Timer stroke variation dT mm 0.5 0.3 0.7

Basic *

_02

Pump speed r/min 1100 1100 1100

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 36 35 37

Timer stroke variation dT mm 0.5 0.2 0.8

_03

Pump speed r/min 1100 1100 1100

Boost pressure kPa 66.65 65.3 68

Boost pressure mmHg 500 490 510

Average injection quantity mm3/st. 25 23.5 26.5

Timer stroke variation dT mm 1.1 0.6 1.6

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.82 5.72 5.92

MS dimension mm 0.9 0.8 1

BCS stroke mm 3.9 3.8 4

Control lever angle alpha deg. 10 6 14

Control lever angle beta deg. 36 31 41

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Potentiometer adjustment 1. Applied voltage: Vi 2. Boost pressure = P1kPa {P2 mmHg} 3. Set the control lever at the adjusting point. Position the dummy bolt against the lever and fix. 4. Assemble the potentiometer to obtain output voltage V1 (V) at the fixed position. 5. After mounting the potentiometer, remove the dummy bolt. N:Pump speed Q:Injection quantity V:Output voltage A:Adjusting point B:Checking point C:Angle of the control lever C1:Idle C2:Full-speed
----------
V1=6.9+-0.03V P1=0kPa P2=0mmHg Vi=10V
----------
N1=1275r/min Q1=12.9+-1.0cm3/1,000st V1=6.9+-0.03V V2=2.0+-1.0V V3=(10)V a=-deg

0000001901 CONTROL LEVER ANGLE

Control lever angle measurement 1. Measure dimension Ya. 2. Measure the lever angle from the pin hole R (plate). (A) = lever reaction force measuring position
----------
Ya=9.6~13.8mm R=53mm
----------
Ya=9.6~13.8mm R=53mm Alpha=6~14deg Beta=31~41deg

Information:

Information Release Memo REM03-28
Reman
September 2003 REMANUFACTURED FUEL INJECTORS FOR VARIOUS INDUSTRIAL, MACHINE, AND ON-HIGHWAY TRUCK APPLICATIONS Announcement The Caterpillar Remanufactured Products Group announces the expansion of the remanufactured injector product line to include additional coverage for various 3126B, 3126E C10, C12, 3176, and 3196 Industrial, Machine, Marine and On-Highway Truck applications. Coverage The addition of these injectors provides dealers with an additional repair option to support various 3126B, 3126E, C10, C12, 3176, and 3196 Industrial, Machine and On-Highway Truck applications. Coverage is extensive so please consult your NPR or Reman Cross Reference for exact model coverage. Features And Benefits Cat? Remanufactured injectors 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 injectors. Cat Remanufactured injectors provide immediate, off-the-shelf availability at a fraction of the new price. Features
All critical engineering changes and updates included
Worldwide availability through Caterpillar? parts distribution system
Backed by Cat warrantyBenefits
Improved reliability and performance
Customer access regardless of location
Consistent supportCore Acceptance Core Acceptance Criteria for Caterpillar Remanufactured injectors is simple, visual, and requires no special tools. Full core credit is issued when the core is complete, fully assembled, and has an acceptable part number. 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 (SELD0039), 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.
PELJ0234 CATERPILLAR? ?2003 Caterpillar