104746-6601 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047466601

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104746-6601 1047466601

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Cross reference number

ZEXEL 104746-6601 1047466601

Zexel num

Bosch num

Firm num

Name

104746-6601

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

Timer measuring device installation position
Low pressure side LOW PRESSURE SIDE

Injection timing adjustment

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 60.5 60 61

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 800 800 800

Boost pressure kPa 52 50.7 53.3

Boost pressure mmHg 390 380 400

Average injection quantity mm3/st. 67.4 66.9 67.9

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 800 800 800

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 76.8 76.3 77.3

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 60.5 59.5 61.5

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 800 800 800

Boost pressure kPa 52 50.7 53.3

Boost pressure mmHg 390 380 400

Average injection quantity mm3/st. 67.4 66.4 68.4

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 800 800 800

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 76.8 75.8 77.8

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 1000 1000 1000

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 83.8 77.3 90.3

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 1250 1250 1250

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 91.5 85 98

Oil temperature degC 50 48 52

Injection timing adjustment_09

Pump speed r/min 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 105.7 99.2 112.2

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2075 2075 2075

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 34 31 37

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 3

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2075 2075 2075

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 34 31 37

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 13.9 11.9 15.9

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 13.9 11.9 15.9

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

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. 60 60 100

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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 1350 1350 1350

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Overflow quantity cm3/min 1080 850 1310

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1350 1350 1350

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure kPa 471 442 500

Pressure kgf/cm2 4.8 4.5 5.1

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1020 1020 1020

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure kPa 353 314 392

Pressure kgf/cm2 3.6 3.2 4

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure kPa 432 393 471

Pressure kgf/cm2 4.4 4 4.8

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1350 1350 1350

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure kPa 471 442 500

Pressure kgf/cm2 4.8 4.5 5.1

Basic *

Oil temperature degC 50 48 52

Stop lever angle_05

Pump speed r/min 1500 1500 1500

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure kPa 510 471 549

Pressure kgf/cm2 5.2 4.8 5.6

Oil temperature degC 50 48 52

Stop lever angle_06

Pump speed r/min 1800 1800 1800

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure kPa 628 589 667

Pressure kgf/cm2 6.4 6 6.8

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1350 1350 1350

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke mm 1.8 1.6 2

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1020 1020 1020

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke mm 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1350 1350 1350

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke mm 1.8 1.6 2

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke mm 3 2.6 3.4

Oil temperature degC 50 48 52

_05

Pump speed r/min 1800 1800 1800

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke mm 4.5 4.2 4.9

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 3.6 3.5 3.7

KF dimension mm 7.76 7.66 7.86

MS dimension mm 0.8 0.7 0.9

BCS stroke mm 2.6 2.4 2.8

Pre-stroke mm 0.2 0.18 0.22

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 37 32 42

Test data Ex:

0000001601 BOOST COMPENSATOR ADJUSTMENT

BCS adjustment procedure 1. At full boost pressure, set so that the full injection quantity is within the specifications (adjusting point). 2. Perform boost compensator intermediate operation point adjustment (pump speed N1, boost pressure P1). 3. When injection quantity at boost pressure P2 and pump speed N2 is not as specified, loosen nut (A) and adjust position of screw (B) so that injection quantity is as specified. The screw position should be within +-1 turn of initial position. 4. The nut tightening torque is T.
----------
N1=800r/min N2=500r/min P1=52.0kPa(390mmHg) P2=0kPa(0mmHg) T=6~9N-m(0.6~0.9kgf-m)
----------
SW=10mm T=6~9N-m(0.6~0.9kgf-m)

0000001801 POTENTIOMETER ADJUSTMENT

Potentiometer adjusting specifications (oval) N:Pump speed Q:Injection quantity P:Boost pressure V:Output voltage C/L: control lever position I:Idle F:Full lever position B:Adjusting point C:Checking point D:Bracket (shape may differ) Adjusting method (applied voltage Vi, dummy bolt method) 1. Hold the dummy bolt (A) against the control lever at position N = N1 and Q = Q1 and fix using the lock nut. 2. At potentiometer adjustment, with the control lever contacting the dummy bolt, adjust the potentiometer so that the output voltage is V1. 3. After completing adjustment, remove the dummy bolt (A) and confirm that the potentiometer output voltage is within the adjustment specifications when the control lever is in the idle position. (A): Dummy bolt and nut part number 146526-3300 (bolt) corresponding to 42 (mm). Corresponding to 013020-6040 (nut)
----------
N1=1080r/min Q1=27.5+-1.0mm3/st V1=3.56+-0.03V Vi=10V
----------
N1=1080r/min N2=375r/min P1=0kPa(0mmHg) Q1=27.5+-1.0mm3/st Q2=13.9+-2.0mm3/st V1=3.56+-0.03V V2=(0.93+-0.45V) V3=(7.10+-0.83V) Vi=10V

Information:

Caterpillar Diesel Truck Engines can operate effectively in cold weather, however, engine operation in cold weather is dependent on the type of fuel used and how well the fuel moves through fuel related components. The purpose of this section is to explain some of the problems and steps that can be taken to minimize fuel problems during cold weather operation when the engine area is colder than 5°C (40°F).Fuel And The Effect From Cold Weather
The two types of diesel fuel available for your engine are typically grades No. 1 and No. 2. Although No. 2 diesel fuel is the most commonly used fuel, No. 1 diesel fuel or a blend of No. 1 and No.2, is the fuel that is best suited for cold weather operation.During cold weather operation, it may be necessary for you to use No. 2 diesel fuel since quantities of No. 1 diesel fuel are limited and generally are only available during the winter months and in the colder climates.There are two major differences between No. 1 and No. 2 diesel fuel. No. 1 diesel fuel has a lower cloud point and a lower pour point.The cloud point is the temperature at which a cloud or haze of wax crystals will begin to form in the fuel and cause fuel filters to plug. The pour point is the temperature which diesel fuel will begin to thicken and be more resistant to flow through fuel pumps and lines.Be aware of these fuel values when purchasing your diesel fuel and anticipate the average outside (ambient) temperature for the area your engine will be operating. Engines fueled in one climate may not operate satisfactorily if moved to another because of problems that result from cold weather. The average No. 1 diesel fuel has a lower kJ (BTU) (heat content) rating per unit volume of fuel than the average No. 2 diesel fuel. When using No. 1 diesel fuel, you may notice a drop in power and fuel efficiency, but should not experience any other operating effects.Before troubleshooting for low power or poor performance in winter months, check the type of fuel being used.The use of starting aids, engine oil pan heaters, engine coolant heaters, fuel heaters and fuel line insulation also provide a means of minimizing starting and fuel problems in cold weather when No. 2 diesel fuel is used.Fuel Related Components In Cold Weather
PEEC Fuel Cooling
Fuel Cooled PEEC ECMThe PEEC electronic control module is fuel cooled. Fuel is routed from the tank, to a primary fuel filter, through the transfer pump, then through cored passages in the electronic control module housing, on to the secondary fuel filter, and finally to the injection pump.Inlet fuel temperature to the transfer pump must never exceed 149°F (65°C). Fuel temperatures in excess of this temperature reduce the life of the electronics, reduce the life of the transfer pump check valves, and reduce engine power availability.Fuel Heaters
Fuel heaters prevent plugging of the fuel filters in cold weather due to waxing. Non-thermostatically