Information injection-pump assembly
ZEXEL
104748-0150
1047480150
MAZDA
R20113800
r20113800

Rating:
Cross reference number
ZEXEL
104748-0150
1047480150
MAZDA
R20113800
r20113800
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
1404 Test oil ISO4113orSAEJ967d
Test oil temperature
degC
45
45
50
Nozzle
105000-2010
Bosch type code
NP-DN12SD12TT
Nozzle holder
105780-2080
Opening pressure
MPa
14.7
14.7
15.19
Opening pressure
kgf/cm2
150
150
155
Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840
Inside diameter - outside diameter - length (mm) mm 2-6-840
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
Right R
Injection timing adjustment
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
38.7
38.2
39.2
Difference in delivery
mm3/st.
2.5
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2400
2400
2400
Average injection quantity
mm3/st.
13.1
10.1
16.1
Injection timing adjustment_03
Pump speed
r/min
2300
2300
2300
Average injection quantity
mm3/st.
23
20
26
Injection timing adjustment_04
Pump speed
r/min
2125
2125
2125
Average injection quantity
mm3/st.
33.9
31.9
35.9
Injection timing adjustment_05
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
39.6
37.6
41.6
Injection timing adjustment_06
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
38.7
37.7
39.7
Injection timing adjustment_07
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
33.4
31.4
35.4
Injection quantity adjustment
Pump speed
r/min
2400
2400
2400
Average injection quantity
mm3/st.
13.1
11.1
15.1
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
2500
2500
2500
Average injection quantity
mm3/st.
3
Governor adjustment
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6
10
Difference in delivery
mm3/st.
2
Basic
*
Governor adjustment_02
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6
10
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
42
42
Basic
*
Speed control lever angle
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF
Magnet OFF
0000000901
Pump speed
r/min
1250
1250
1250
Overflow quantity
cm3/min
430
298
562
Stop lever angle
Pump speed
r/min
1250
1250
1250
Pressure
kPa
510
481
539
Pressure
kgf/cm2
5.2
4.9
5.5
Basic
*
Stop lever angle_02
Pump speed
r/min
500
500
500
Pressure
kPa
294.5
265
324
Pressure
kgf/cm2
3
2.7
3.3
Stop lever angle_03
Pump speed
r/min
1250
1250
1250
Pressure
kPa
510
481
539
Pressure
kgf/cm2
5.2
4.9
5.5
Stop lever angle_04
Pump speed
r/min
2125
2125
2125
Pressure
kPa
745.5
716
775
Pressure
kgf/cm2
7.6
7.3
7.9
0000001101
Pump speed
r/min
1250
1250
1250
Timer stroke
mm
3.9
3.7
4.1
Basic
*
_02
Pump speed
r/min
1250
1250
1250
Timer stroke
mm
3.9
3.6
4.2
_03
Pump speed
r/min
1500
1500
1500
Timer stroke
mm
5.2
4.6
5.8
_04
Pump speed
r/min
2125
2125
2125
Timer stroke
mm
8.8
8.2
9.4
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.
28.2
27.2
29.2
Timer stroke TA
mm
3.1
2.9
3.3
Basic
*
_02
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
28
26.5
29.5
Timer stroke TA
mm
3.1
2.8
3.4
_03
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
18
16.5
19.5
Timer stroke TA
mm
1.9
1.2
2.6
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.8
5.7
5.9
MS dimension
mm
1.5
1.4
1.6
Control lever angle alpha
deg.
30
26
34
Control lever angle beta
deg.
45
40
50
Test data Ex:
0000001801 M-CSD ADJUSTMENT

M-CSD adjustment
1. Fixing the M-CSD
(1)At roller holder advance angle a adjust the lever shaft ball pin so that it contacts the roller holder.
(2)At this time, adjust the position of the M-CSD lever (A) using adjusting screw (C) so that the clearance between the M-CSD lever (A) and the stopper (B) becomes L1. Then fix using nut (D).
TT
2. M-FICD adjustment
(1)Move the CSD lever (A) through its full stroke.
(2)Adjust screw (E) so that the control lever (G)'s position is b (the clearance between the control lever and the idling set screw is L2). Then fix using the nut (F).
TT
Pump speed NE
H = from idle to position b
----------
L1=0.5+2mm L2=4.8+-1mm a=0deg b=7deg T=6~9N-m(0.6~0.9kgf-m)
----------
L1=0.5+2mm L2=4.8+-1mm T=6~9N-m(0.6~0.9kgf-m) b=7deg
----------
L1=0.5+2mm L2=4.8+-1mm a=0deg b=7deg T=6~9N-m(0.6~0.9kgf-m)
----------
L1=0.5+2mm L2=4.8+-1mm T=6~9N-m(0.6~0.9kgf-m) b=7deg
Information:
Oil Filters (1), Crankcase Drain (2), Oil Filler (3), Oil Level Gauge (4), Fuel Filters & Priming Pump (5), Air Cleaner with Service Indicator (6), Aftercooler (7), Turbochargers (8), Crankcase Breather with Element (9), Alternator (10), Electronic Governing/Control Module (11), Primary Fuel Filter (12), Oil Cooler (13), Magnetic Speed Sensor (14), Jacket Water Pump (15), Jacket Water Heater (16), Fumes Disposal Drain (17), Ether Canister Bracket (18), Starting Motor (19) and Cooling System Drain (20).
Main Control (GSC) Panel (21), Emergency Stop Pushbutton (22), Engine Control Switch (23), Alarm Module (24).Engine Description
Caterpillar 3412 Generator Set Engines are 27 liter (1649 cu. in.), 137 mm (5.4 in.) bore and 152.4 mm (6.0 in.) stroke, four cycle, 12 cylinder, 65 degree vee diesel design. The engine is available in twin turbocharged or series turbocharged arrangements with jacket water aftercooling and direct fuel injection.The engine and components are designed for high power output. The reduced size and weight plus increased fuel economy provide maximum performance and lower cost per unit of power. The 3412 Generator Set is offered at 1500 rpm, 50 Hz and 1800 rpm, 60 Hz arrangements with various output power ratings. Contact your Caterpillar dealer for information on these 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.The engine lubricating oil, which is both cooled and filtered, is supplied by a gear driven pump. Bypass valves provide unrestricted flow of lubrication oil to engine parts when oil viscosity is high, or either the oil cooler or oil filter elements should become plugged.The 3412 Generator Set Engine is electronically governed and features an exclusive electronic Engine Control Module (ECM). The ECM is a microprocessor-based system that provides full range isochronous speed governing which can operate in speed droop with a zero to ten percent adjustment range.The ECM also provides a cold mode starting strategy, air to fuel ratio control for transient smoke limiting, automatic turbocharger boost pressure and rack position sensor calibration, engine protection and diagnostics.The 3412 engines are equipped with the Electronic Modular Control Panel (EMCP II). The EMCP II is the next generation of engine/generator controls for more accurate, reliable monitoring of engine operating parameters and generator AC voltage metering.The SR4 generator features single bearing, wye connected, brushless, permanent magnet excited designed to match the output characteristics of the engine. These packaged generator sets are designed, manufactured and tested in accordance with ISO 9001 to ensure the highest possible quality on a worldwide basis.Engine efficiency and engine performance and efficiency of emissions controls depend on adherence to proper operation and maintenance recommendations, and the use of recommended fuels, coolants and lubrication oils. To minimize expenses and provide maximum utilization and performance of your