Information injection-pump assembly
ZEXEL
104740-1881
1047401881
ISUZU
8970255451
8970255451
Rating:
Cross reference number
ZEXEL
104740-1881
1047401881
ISUZU
8970255451
8970255451
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
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
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
Right R
Injection timing adjustment
Pump speed
r/min
1290
1290
1290
Average injection quantity
mm3/st.
48.6
48.1
49.1
Difference in delivery
mm3/st.
3.5
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2500
2500
2500
Average injection quantity
mm3/st.
15.4
11.9
18.9
Injection timing adjustment_03
Pump speed
r/min
2150
2150
2150
Average injection quantity
mm3/st.
45.9
42.9
48.9
Injection timing adjustment_04
Pump speed
r/min
1290
1290
1290
Average injection quantity
mm3/st.
48.6
47.6
49.6
Injection timing adjustment_05
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
45.8
42.8
48.8
Injection quantity adjustment
Pump speed
r/min
2500
2500
2500
Average injection quantity
mm3/st.
15.4
12.4
18.4
Difference in delivery
mm3/st.
4.5
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
2850
2850
2850
Average injection quantity
mm3/st.
5
Governor adjustment
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
10.5
8.5
12.5
Difference in delivery
mm3/st.
2
Basic
*
Governor adjustment_02
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
3
Governor adjustment_03
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
10.5
8.5
12.5
Timer adjustment
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
55
75
Basic
*
Speed control lever angle
Pump speed
r/min
425
425
425
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
420
288
552
Stop lever angle
Pump speed
r/min
1750
1750
1750
Pressure
kPa
588.5
569
608
Pressure
kgf/cm2
6
5.8
6.2
Basic
*
Stop lever angle_02
Pump speed
r/min
600
600
600
Pressure
kPa
323.5
294
353
Pressure
kgf/cm2
3.3
3
3.6
Stop lever angle_03
Pump speed
r/min
1250
1250
1250
Pressure
kPa
470.5
441
500
Pressure
kgf/cm2
4.8
4.5
5.1
Stop lever angle_04
Pump speed
r/min
1750
1750
1750
Pressure
kPa
588.5
569
608
Pressure
kgf/cm2
6
5.8
6.2
Stop lever angle_05
Pump speed
r/min
2150
2150
2150
Pressure
kPa
676.5
647
706
Pressure
kgf/cm2
6.9
6.6
7.2
0000001101
Pump speed
r/min
1750
1750
1750
Timer stroke
mm
4.2
4
4.4
Basic
*
_02
Pump speed
r/min
1250
1250
1250
Timer stroke
mm
2
1.4
2.6
_03
Pump speed
r/min
1750
1750
1750
Timer stroke
mm
4.2
3.9
4.5
_04
Pump speed
r/min
2150
2150
2150
Timer stroke
mm
5.85
5.3
6.4
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001401
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
35
34
36
Timer stroke variation dT
mm
0.4
0.2
0.6
Basic
*
_02
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
35
33.5
36.5
Timer stroke variation dT
mm
0.4
0.1
0.7
_03
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
25
23.5
26.5
Timer stroke variation dT
mm
1
0.5
1.5
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.5
5.4
5.6
MS dimension
mm
0.9
0.8
1
Pre-stroke
mm
0.2
0.18
0.22
Control lever angle alpha
deg.
-2
-6
2
Control lever angle beta
deg.
38
33
43
Test data Ex:
0000001801 A/T PLATE ADJUSTMENT
A/T plate adjustment
1. Turn the control lever from the idle position (B) to the Full speed position (C)
2. Adjust the A/T plate (D) so that (A)(C) - (A)(B) = L3, then fix.
----------
L3=33+-0.5mm
----------
L1=95.5mm L2=109.5mm L3=33+-0.5mm T=3.5~5N-m(0.35~0.5kgf-m)
----------
L3=33+-0.5mm
----------
L1=95.5mm L2=109.5mm L3=33+-0.5mm T=3.5~5N-m(0.35~0.5kgf-m)
Information:
Exhaust Smoke Can Be Seen While Starting
Possible Causes/Corrections Cold Outside TemperaturesIt may be necessary to use starting aids, or to heat engine oil or coolant at temperatures below -12°C (10°F).Air in Fuel System
With air in the fuel system, the engine will normally be difficult to start, run rough, and release a large amount of white smoke. If the engine will not start, loosen a fuel injection line nut at the through the head adapter and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine still does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the through the head adapters until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air can not be removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leakage at the connections between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. It there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.Low Quality Fuel
Remove a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, remove fuel from the tank until it is free of water and fill with good quality fuel. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines.Change the fuel filter and "prime" (remove the air and/or low quality fuel from the fuel system) the fuel system with the fuel priming pump. If there is no water in the fuel, prime and start the engine by using an outside source of fuel. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel. Prime the fuel system if necessary.Low Fuel Pressure
Change the primary and secondary fuel filters and check to make sure the fuel lines are not plugged or damaged. If the filters or lines are not the cause, a repair or replacement of the fuel transfer pump is needed.Fuel Injection Timing Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual.Valve Adjustment Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in) and exhaust valve clearance is 0.76 mm (.030 in).Bad Fuel Nozzle(s)
Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual.Low Compression
See Misfiring and Running Rough.Exhaust Smoke Cannot Be Seen While Starting
Possible Causes/CorrectionsNo Fuel in Tank(s)
Check fuel level visually (do not
Possible Causes/Corrections Cold Outside TemperaturesIt may be necessary to use starting aids, or to heat engine oil or coolant at temperatures below -12°C (10°F).Air in Fuel System
With air in the fuel system, the engine will normally be difficult to start, run rough, and release a large amount of white smoke. If the engine will not start, loosen a fuel injection line nut at the through the head adapter and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine still does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the through the head adapters until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air can not be removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leakage at the connections between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. It there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.Low Quality Fuel
Remove a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, remove fuel from the tank until it is free of water and fill with good quality fuel. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines.Change the fuel filter and "prime" (remove the air and/or low quality fuel from the fuel system) the fuel system with the fuel priming pump. If there is no water in the fuel, prime and start the engine by using an outside source of fuel. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel. Prime the fuel system if necessary.Low Fuel Pressure
Change the primary and secondary fuel filters and check to make sure the fuel lines are not plugged or damaged. If the filters or lines are not the cause, a repair or replacement of the fuel transfer pump is needed.Fuel Injection Timing Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual.Valve Adjustment Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in) and exhaust valve clearance is 0.76 mm (.030 in).Bad Fuel Nozzle(s)
Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual.Low Compression
See Misfiring and Running Rough.Exhaust Smoke Cannot Be Seen While Starting
Possible Causes/CorrectionsNo Fuel in Tank(s)
Check fuel level visually (do not