104746-6231 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047466231

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104746-6231 1047466231

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Cross reference number

ZEXEL 104746-6231 1047466231

Zexel num

Bosch num

Firm num

Name

104746-6231

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 1150 1150 1150

Average injection quantity mm3/st. 51.4 50.9 51.9

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. 30.3 26.8 33.8

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 33.9 30.4 37.4

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 51.4 50.4 52.4

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 2050 2050 2050

Average injection quantity mm3/st. 58.3 53.8 62.8

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 40.6 37.6 43.6

Difference in delivery mm3/st. 8

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 12

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 40.6 37.6 43.6

Difference in delivery mm3/st. 8

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 8.4 6.4 10.4

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 8.4 6.4 10.4

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. 60 60 100

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 60 100

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 375 375 375

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 1400 1400 1400

Overflow quantity cm3/min 370 240 500

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1400 1400 1400

Pressure kPa 412 392 432

Pressure kgf/cm2 4.2 4 4.4

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1400 1400 1400

Pressure kPa 412 392 432

Pressure kgf/cm2 4.2 4 4.4

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1400 1400 1400

Timer stroke mm 3.3 3.1 3.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Timer stroke mm 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1400 1400 1400

Timer stroke mm 3.3 3.1 3.5

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1600 1600 1600

Timer stroke mm 4.8 4.4 5.2

Oil temperature degC 50 48 52

_05

Pump speed r/min 1900 1900 1900

Timer stroke mm 6.1 5.8 6.5

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001501

Pump speed r/min 1150 1150 1150

Height m 2000 2000 2000

Atmospheric pressure difference kPa -21.9 -21.9 -21.9

Atmospheric pressure difference mmHg -164 -164 -164

Average injection quantity mm3/st. 42.5 41.5 43.5

Decrease qty mm3/st. 9.3 9.3 9.3

Decrease rate % 18 15 21

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1150 1150 1150

Height m 0 0 0

Atmospheric pressure difference kPa 0 0 0

Atmospheric pressure difference mmHg 0 0 0

Decrease qty mm3/st. 0 0 0

Decrease rate % 0 0 0

Oil temperature degC 50 48 52

_03

Pump speed r/min 1150 1150 1150

Height m 500 500 500

Atmospheric pressure difference kPa -5.9 -9.2 -2.6

Atmospheric pressure difference mmHg -44 -69 -19

Oil temperature degC 50 48 52

Remarks
Point of inflection

_04

Pump speed r/min 1150 1150 1150

Height m 2000 2000 2000

Atmospheric pressure difference kPa -21.9 -21.9 -21.9

Atmospheric pressure difference mmHg -164 -164 -164

Decrease qty mm3/st. 9.3 7.8 10.8

Decrease rate % 18 15 21

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.1 3 3.2

KF dimension mm 5.5 5.4 5.6

MS dimension mm 0.8 0.7 0.9

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 37 32 42

Test data Ex:

0000001801 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the advance angle of the timer (1)Determine the timer advance angle from the graph in Fig. 2 (D). (2)(1) Adjust with the screw so that the timer advance angle determined in the item (1) is obtained. (C) Fig. 1 (D) Fig. 2 (A): TA+-0.1 (B): Timer stroke TA: X:Temperature X Y:Timer stroke TA (mm)
----------

----------
(B)=-10<=t(degC)<=20:TA=-0.0367t+1.284 (D)=20<=t(degC)<=40:TA=-0.0275t+1.1

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Adjust the actuator rod to obtain L1mm. 2. Apply negative pressure of P1kPa {P2 mmHg} to the actuator and confirm that it moves through its full stroke. A:Control lever idling position
----------
L=1+1mm P1=-53.3kPa P2=-400mmHg
----------
T1=3.4~4.9N-m{0.35~0.5kgf-m} T2=1.4~2.0N-m{0.14~0.2kgf-m} L=1+1mm

Information:

Engine Model View
3408 Engine Shown
Turbochargers (1), Exhaust Outlet (2), Crankcase Breather (3), Lifting Eye (4), Flywheel (5), Magnetic Pickup (6), Electronic Control Module (ECM) (7), Oil Fill Tube (8), Thermostat (9), Primary Fuel Filter (10), Water Pump (11), Crankshaft Vibration Damper (12), Alternator (13), Oil Filters (14), Crankcase Drain Plug (15), Fuel Filters and Priming Pump (16).3408 Engine Description
Caterpillar 3408 electronically controlled Industrial Engines are 18 liter (1099 cu in), 137 mm (5.4 in) bore and 152.4 mm (6.0 in) stroke, four cycle, 8 cylinder, 65 degree vee diesel design. The engine is twin turbocharged with jacket water aftercooling and direct fuel injection. It is designed for petroleum and auxiliary industrial applications.The engine and components are designed for high power output. The reduced size and weight plus increased fuel economy provide maximum performance. Contact your Caterpillar dealer for information on power ratings.Larger diameter plungers and a higher injection rate camshaft are incorporated in the valve train/fuel system. The fuel lines are made of high strength steel and the ends of the lines have collared washers to increase reliability.The cooling system has a gear driven centrifugal water pump, two thermostats (one for each bank) which regulate engine coolant temperature, and an oil cooler. A customer supplied fan drive and cooling system (radiator) may be required for the industrial