104749-2441 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047492441

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104749-2441 1047492441

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Cross reference number

ZEXEL 104749-2441 1047492441

Zexel num

Bosch num

Firm num

Name

104749-2441

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
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

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 900 900 900

Average injection quantity mm3/st. 30.4 30 30.8

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 30.6 28.6 32.6

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 30.4 29.4 31.4

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 31.8 29.8 33.8

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 30.8 28.8 32.8

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 30.5 28.5 32.5

Oil temperature degC 52 50 54

Injection timing adjustment_07

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 30.2 28.2 32.2

Oil temperature degC 55 52 58

Injection quantity adjustment

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 14.5 12.5 16.5

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. 14.5 11 18

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 6

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 5.2 4.2 6.2

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 5.2 3.2 7.2

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 3

Oil temperature degC 48 46 50

Boost compensator adjustment

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 12.1 7.6 16.6

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 7.2 7.2 7.2

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 7 2 12

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 7.2 7.2 7.2

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50 40 60

Basic *

Oil temperature degC 48 46 50

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50 40 60

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

Speed control lever angle_02

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 50 48 52

Remarks
Magnet OFF at full-load position

0000000901

Pump speed r/min 900 900 900

Overflow quantity cm3/min 330 200 460

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 900 900 900

Pressure kPa 343 314 372

Pressure kgf/cm2 3.5 3.2 3.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 900 900 900

Pressure kPa 343 304 382

Pressure kgf/cm2 3.5 3.1 3.9

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Pressure kPa 539.5 500 579

Pressure kgf/cm2 5.5 5.1 5.9

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2300 2300 2300

Pressure kPa 706 667 745

Pressure kgf/cm2 7.2 6.8 7.6

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 900 900 900

Timer stroke mm 1.5 1.3 1.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Timer stroke mm 1.5 1.2 1.8

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1200 1200 1200

Timer stroke mm 3 2.7 3.3

Oil temperature degC 50 48 52

_04

Pump speed r/min 2300 2300 2300

Timer stroke mm 8.4 7.8 9

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 1.2 1.1 1.3

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 41 36 46

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer (1)At pump speed N1 and oil temperature t, and at lever angle a from the idle position (shim thickness L), determine the voltage value from the graph using the injection quantity obtained. Then adjust the potentiometer. V+-0.05 = 0.155323Q + 2.43145 (applied voltage Vi) (2)With the control lever turned to the full speed side, confirm that voltage increases. (3)Confirm V1 at idling. Q:Injection quantity
----------
N1=600(r/min) t=48~52(deg) a=11(deg) L=7.2+-0.05(mm) Vi=10(V) V1=1.16+-0.9(V)
----------

0000001901 M-CSD ADJUSTMENT

M-CSD adjustment 1. Fixing intermediate lever screw (A) [roller (E) must not contact intermediate lever (D)] (1)Hold the control lever (C) in the idling position. (2)At this time, adjust screw (A) so that it is horizontal and the clearance between screw (A) and the control lever (C) is L1. Then, fix using nut (B). 2. Fixing the M-CSD stopper (I) Pull the CSD lever (F) in the direction X until it contacts the stopper (I) and tighten the socket head bolt (J) when the timer advance angle is L2. 3. Screw (G) adjustment Pull the CSD lever (F) in the direction X until it contacts the stopper (I) and adjust the screw (G) so that the control lever shim thickness is L3. Then, tighten nut (H).
----------
L1=1~2(mm) L2=1.23+-0.2(mm) L3=7.2+-0.5(mm)
----------
T1=6~9(N-m)(0.6~0.9(kgf-m)) T2=5~7(N-m)(0.5~0.7(kgf-m)) T3=2~3(N-m)(0.2~0.3(kgf-m)) L1=1~2(mm) L3=7.2+-0.5(mm)

Information:

Solution
Caterpillar is aware of this problem and is recommending the following interim corrective action. Please follow the Special Instruction, M0110497, "Removal and Installation Procedure for DEF Heated Lines on Certain Machine Engines" for proper Disassembly and Assembly of the DEF heated lines to avoid failures. If a failure or DEF leak is noted even after following the special instructions, please use Service Magazine, M0103829, "Diesel Exhaust Fluid (DEF) Heated Lines May Be Damage on Certain Cat® Machines" for a temporary line repair. If additional help is needed, please go to the Parts Tech tab and enter a Product Health ticket in PSCRM.The new hose assemblies are listed in Table 1.
Table 1
Item Qty New Part Number Part Name
1 1 457-9011 Return Hose Assembly
2 1 457-9013 Return Hose Assembly
3 1 457-9026 Return Hose Assembly
4 1 457-9027 Return Hose Assembly
5 1 462-4206 Hose As
6 1 462-4210 Hose As
7 1 462-4211 Hose As
8 1 462-4219 Hose As
9 1 462-4220 Hose As
10 1 462-4221 Hose As
11 1 462-4223 Hose As
12 1 462-4224 Hose As
13 1 475-3231 Hose As
14 1 475-3232 Hose As
15 1 475-3233 Hose As
16 1 475-3234 Hose As
17 1 475-9989 Hose As
18 1 478-9071 Hose As
19 1 478-9072 Hose As
20 1 478-9074 Hose As
21 1 478-9075 Hose As
22 1 478-9077 Hose As
23 1 478-9078 Hose As
24 1 478-9079 Hose As
25 1 478-9081 Hose As
26 1 478-9082 Hose As
27 1 478-9083 Hose As
28 1 478-9085 Hose As
29 1 478-9086 Hose As
30 1 497-9305 Hose As
31 1 497-9306 Hose As
32 1 497-9307 Hose As
33 1 497-9308 Hose As
34 1 500-6215 Return Hose Assembly
35 1 500-6216 Return Hose Assembly
36 1 500-6217 Hose As
37 1 500-6218 Hose As
38 1 500-6219 Hose As
39 1 500-6220 Hose As
40 1 500-6221 Hose As
41 1 500-6222 Hose As
42 1 500-6223 Hose As
43 1 500-6224 Hose As
44 1 510-5191 Return Hose Assembly
45 1 510-5192 Hose As
46 1 510-5193 Hose As
47 1 510-5194 Hose As
48 1 552-3292 Hose As
49 1 552-3293 Hose As
50 1 552-3294 Hose As
51 1 552-3295 Hose As
52 1 579-9200 Hose As
53 1 579-9201 Hose As
54 1 579-9202 Hose As
55 1 579-9203 Hose As