104741-1001 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411001 8941337571

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-1001 1047411001

ISUZU 8941337571 8941337571

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Cross reference number

ZEXEL 104741-1001 1047411001

ISUZU 8941337571 8941337571

Zexel num

Bosch num

Firm num

Name

104741-1001
104741-1120

8941337571 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1B * K

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

(Solenoid timer adjustment condition)
OFF OFF

Timer measuring device installation position
Low pressure side LOW PRESSURE SIDE

Injection timing adjustment

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 47.5 47 48

Difference in delivery mm3/st. 4

Basic *

Injection timing adjustment_02

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 13.1 9.6 16.6

Injection timing adjustment_03

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 47.4 44.9 49.9

Injection timing adjustment_04

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 48.4 46.4 50.4

Injection timing adjustment_05

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 47.5 46.5 48.5

Injection timing adjustment_06

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 42.35 40.3 44.4

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 13.1 10.1 16.1

Difference in delivery mm3/st. 4

Basic *

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 5

Governor adjustment

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 8 6 10

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 8 6 10

Governor adjustment_03

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 3

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 75 115

Basic *

Speed control lever angle

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1600 1600 1600

Overflow quantity with S/T OFF cm3/min 531 402 660

Remarks
OFF

Stop lever angle

Pump speed r/min 1600 1600 1600

Pressure kPa 539.5 520 559

Pressure kgf/cm2 5.5 5.3 5.7

Basic *

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Pressure kPa 313.5 284 343

Pressure kgf/cm2 3.2 2.9 3.5

Stop lever angle_03

Pump speed r/min 1600 1600 1600

Pressure kPa 539.5 520 559

Pressure kgf/cm2 5.5 5.3 5.7

Stop lever angle_04

Pump speed r/min 1900 1900 1900

Pressure kPa 627.5 598 657

Pressure kgf/cm2 6.4 6.1 6.7

0000001101

Pump speed r/min 1600 1600 1600

Timer stroke mm 1.9 1.7 2.1

Basic *

_02

Pump speed r/min 790 690 890

Timer stroke with S/T ON mm 0.5 0.5 0.5

_03

Pump speed r/min 1490 1440 1540

Timer stroke with S/T OFF mm 0.5 0.5 0.5

_04

Pump speed r/min 1600 1600 1600

Timer stroke with S/T OFF mm 1.9 1.6 2.2

_05

Pump speed r/min 1900 1900 1900

Timer stroke with S/T OFF mm 5.7 5.3 6.1

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 2.8 2.7 2.9

KF dimension mm 5 4.9 5.1

MS dimension mm 1 0.9 1.1

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 35 30 40

Information:

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Remove any coolant lines that may interfere with the installation. Remove any air inlet lines that may interfere with the installation.
Illustration 1 g01006397
Typical example (1) Bolt (2) Washer (3) Air inlet cover
Remove bolt (1) and the washer (2) from the air inlet cover (3). Discard the bolt (1) and the washer (2) .
Disconnect the electrical connector of the injection actuation pressure control valve (7). Remove the injection actuation pressure control valve (7) from the pump. Retain the injection actuation pressure control valve (7) for the reinstallation.Note: Modifications to the tools may need to be made in order to reduce interference with engine components.
Illustration 2 g01007381
Modified 2P-5494 crowfoot wrench
Remove the hose assembly (5), the connector (8), and the elbow (6). Discard these parts.
Illustration 3 g01006381
(4) HEUI pump (5) Flexible oil line (6) Elbow (7) Injection actuation pressure control valve (8) ConnectorInstallation of the 240-0716 Tube Kit
Illustration 4 g01006407
(4) HEUI pump (7) Injection actuation pressure control valve (9) Connector (10) Clip (11) Washer (12) Bolt (13) Spacer (14) Tube assembly (15) O-ring (16) O-ring (17) Elbow
Illustration 5 g01006437
(7) Injection actuation pressure control valve (9) Connector (15) O-ring (16) O-ring (17) Elbow
Apply a light coat of oil to the O-rings (15) and (16) during installation. Install the O-ring (15) on the connector (9). Install the O-ring (16) on the connector (9). Thread the connector (9) into the port on the cylinder head by hand. Tighten to 48 + 5 N m (35 + 4 lb ft).
Apply a light coat of oil to the O-rings (15) and (16) during installation. Install the O-ring (15) on the elbow (17). Install the O-ring (16) on the elbow (17).
Back off the jam nut on the elbow (17) to the top of the threads on the elbow assembly (17). Push the washer tightly against the jam nut. Check that the washer is as tight as possible. Thread the elbow assembly (17) into the port of the HEUI pump (4). Hand tighten the elbow (17) into the port of the HEUI pump until the washer is tight against the HEUI pump (4). Unscrew the elbow assembly (17) no more than one complete turn to 40 degrees.
Align the tube assembly (14) with the connector (9) and the elbow (17). Loosely thread each end of the tube assembly (14) onto the connector (9) and the elbow (17). Position the elbow (17) in order to not create stress in the tube assembly (14) .
Attach the clip (10) to the tube assembly (14). The flat side of the clip (10) must be toward the air inlet cover. Place the washer (11) onto the bolt