104749-5370 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047495370

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104749-5370 1047495370

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Cross reference number

ZEXEL 104749-5370 1047495370

Zexel num

Bosch num

Firm num

Name

104749-5370

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 750 750 750

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Average injection quantity mm3/st. 44.3 43.8 44.8

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 49.7 49.2 50.2

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 38.8 35.8 41.8

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Average injection quantity mm3/st. 44.3 43.3 45.3

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 750 750 750

Boost pressure kPa 33.3 32 34.6

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 46.5 44 49

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1500 1500 1500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 36.1 33.6 38.6

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 49.7 48.7 50.7

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 2250 2250 2250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 51.3 48.3 54.3

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2750 2750 2750

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 24.4 21.4 27.4

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2950 2950 2950

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 4

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2750 2750 2750

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Average injection quantity mm3/st. 24.4 21.4 27.4

Difference in delivery mm3/st. 5.5

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10.2 8.2 12.2

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10.2 8.2 12.2

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 150 150 150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 40 30 50

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 150 150 150

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 40 30 50

Oil temperature degC 48 46 50

Remarks
IDLE

Speed control lever angle

Pump speed r/min 425 425 425

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 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Overflow quantity cm3/min 630 500 760

Oil temperature degC 50 48 52

Remarks
Full

_02

Pump speed r/min 425 425 425

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 450 320 580

Oil temperature degC 48 46 50

Remarks
IDLE

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

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 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

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 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 4.7 4.5 4.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 600 600 600

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 0.5 0.1 1.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 4.7 4.5 4.9

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1500 1500 1500

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 6.3 5.9 6.7

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 72 70.7 73.3

Boost pressure mmHg 540 530 550

Timer stroke mm 9 8.7 9.4

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 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 0.9 0.8 1

Control lever angle alpha deg. 20 16 24

Control lever angle beta deg. 40 35 45

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjusting method (applied voltage Vi, dummy bolt method) 1. Hold the dummy bolt against the control lever when N=N1, Q=Q1. Fix using the locknut. 2. When adjusting the potentiometer, position the control lever against the dummy bolt and adjust the potentiometer so that the output voltage is V1. 3. After completing adjustment remove the dummy bolt. Confirm that the potentiometer output voltage is as specified above at the control lever idle position and full position. N:Pump speed V:Output voltage Q:Injection quantity P:Boost pressure A:Adjusting point B:Checking point R:Lever position R1:Idle R2:Full speed (C) Nut 013020-6040 (D) Dummy bolt 146526-3300
----------
N1=750r/min V1=2.76+-0.03V Q1=13.8+-1.0cm3/1,000st Vi=10V
----------
N1=750r/min V1=2.76+-0.03V V2=0.97+-0.45V V3=7.63+-0.65V Q1=13.8+-0.65cm3/1,000st

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD (perform with W-FICD released) 1. Adjust to obtain L1. 2. Confirm that L2 is obtained when negative pressure P1 (kPa) {P2 (mmHg)} is applied to the actuator. Adjust the stroke using the actuator stroke adjusting screw (F). (A): Pin (B): Actuator shaft (C): Control lever (D): Actuator (E): Lock nut (torque T)
----------
L1=1+1mm L2=0.84+-0.1mm P1=-53.3kPa P2=-400mmHg
----------
L1=1+1mm L2=0.84+-0.1mm T=1.2~1.5N-m{0.12~0.15kgf-m}

0000002001 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the timer stroke Adjust screw (A) so that the timer stroke is the value determined from the graph. 2. Adjustment of the position of the intermediate lever. Insert a shim L between the control lever I and the idle setscrew G. Align the intermediate lever (F) with the aligning line and fix screw intermediate lever's adjusting (E) so that it contacts the control lever. 3. Adjustment of the FICD Insert a shim LT between the control lever I and the idle setscrew G. Use adjusting screw (B) to fix the CSD lever (C) in the position where it operates the intermediate lever via the rod (D). (J) Aligning mark (O) = timer stroke adjustment (mm): TA = -0.041t+2.42 (P) Lever position (deg): theta 1 = -0.108t+4.79 (-20 deg C <= t <= 20 deg C) Theta 2 = -0.133t + 5.29 (20 deg C =< t =< 50 deg C) (Q) Lever position (mm): L1 = -0.035t+1.57 (-20 deg C <= t <= 20 deg C) L2 = -0.044t + 1.75 (20 deg C =< t =< 50 deg C) The (Q) indicates the clearance between the control lever and the idle set screw. X:Temperature t (deg C) Y1:Timer stroke TA (mm) Y2:Control lever position at theta L (deg, mm) (R) Cooling water temperature (deg C) (S) Cooling water temperature: increase direction N:Pump speed (r/min) (M) Timer piston stroke (mm) (K) Lever angle (deg) (Z) Lever position (mm)
----------
L=1.2+-0.05mm LT=L+-0.05mm
----------
L=1.2+-0.05mm N1=500r/min R1=20degC R2=-20degC M1=1.9+-0.4mm M2=3.4+-0.6mm K1=3.6+-1deg K2=7.9+-3deg Z1=1.2+-0.3mm Z2=2.6+-1mm

Information:

AFFECTED PRODUCT
Model Identification Number
D6R III GMT00101-00170
HCD00123-00155
TBC00100-00191
D6R III LGP DMK00130-00208
JWD00250
LGP00164-00166
WRG00158-00564
D6R III XL GJB00173-00622
JDL00113-00202
LAE00125
LFM00111-00180
D6R III XW DPS00120-00132
MRT00163-00387
D6R IIIP LGP DLM00161-00162
WCB00112-00184
D6R IIIP XL HKE00146-00221
RFC00140
D6R IIIP XW DJG00250-00251
HDC00133-00211
MTJ00151-00152
PARTS NEEDED
No parts needed for this program
ACTION REQUIRED
Please refer to the attached Rework Procedure.
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification.
SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 1.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR FLASHING INJECTOR ETRIM FILES
MODELS INVOLVED - CERTAIN D6R III, D6R IIIP XW, D6R IIIP LGP, D6R III LGP, D6R III XW, AND D6R III XL TRACK TYPE TRACTORS
Dear Caterpillar Product Owner:
New injector etrim files need to be installed on the products listed below. The upgraded files will help performance and stability of your D6R engine. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
Please refer the dealer to their Service Letter dated 31Aug2006 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 31Aug2006 Service Letter
Rework Procedure
Field Rework Procedure
1. Using the provided machine serial number of the D6R Series III tractor in your service area, go to TMI web and look up the engine serial number.
2. Look up your engine serial number on the Excell file emailed to all machine TCs in order to access the injector serial numbers. If you don't have a copy of this file go the the Knowledge Network to get the file from the following web address: https://kn.cat.com/message.cfm?id=4388&parent=153301&type=Broadcast
3. Copy the 6 injector serial numbers for each machine in your service area and go to SIS web.
4. At the main menu click on Service Software Files.
5. Follow the directions and down load the trim file for each injector, putting them on a disk or in a file that can be accessed from ET.
6. Down load the six trim files for the injectors and program into the ECM in the correct order, using ET.
7. Make sure the machine SN and /or engine SN are included in the service letter claim