Information injection-pump assembly
ZEXEL
104741-1041
1047411041
ISUZU
8941337551
8941337551
Rating:
Cross reference number
ZEXEL
104741-1041
1047411041
ISUZU
8941337551
8941337551
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
(Solenoid timer adjustment condition)
OFF OFF
OFF OFF
Timer measuring device installation position
Low pressure side LOW PRESSURE SIDE
Low pressure side LOW PRESSURE SIDE
Injection timing adjustment
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
43
42.5
43.5
Difference in delivery
mm3/st.
3.5
Basic
*
Injection timing adjustment_02
Pump speed
r/min
2250
2250
2250
Average injection quantity
mm3/st.
16.1
12.6
19.6
Injection timing adjustment_03
Pump speed
r/min
1900
1900
1900
Average injection quantity
mm3/st.
39.8
37.3
42.3
Injection timing adjustment_04
Pump speed
r/min
1350
1350
1350
Average injection quantity
mm3/st.
44.2
42.2
46.2
Injection timing adjustment_05
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
43
42
44
Injection timing adjustment_06
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
38.5
36.5
40.5
Injection timing adjustment_07
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
39.05
35.5
42.6
Injection quantity adjustment
Pump speed
r/min
2250
2250
2250
Average injection quantity
mm3/st.
16.1
13.1
19.1
Difference in delivery
mm3/st.
4.5
Basic
*
Injection quantity adjustment_02
Pump speed
r/min
2350
2350
2350
Average injection quantity
mm3/st.
12
Governor adjustment
Pump speed
r/min
390
390
390
Average injection quantity
mm3/st.
7.5
5.5
9.5
Difference in delivery
mm3/st.
2
Basic
*
Governor adjustment_02
Pump speed
r/min
390
390
390
Average injection quantity
mm3/st.
7.5
5.5
9.5
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.
90
75
105
Basic
*
Speed control lever angle
Pump speed
r/min
390
390
390
Average injection quantity
mm3/st.
0
0
0
Remarks
Magnet OFF
Magnet OFF
0000000901
Pump speed
r/min
1550
1550
1550
Overflow quantity with S/T OFF
cm3/min
531
402
660
Stop lever angle
Pump speed
r/min
1550
1550
1550
Pressure with S/T OFF
kPa
519.5
500
539
Pressure with S/T OFF
kgf/cm2
5.3
5.1
5.5
Basic
*
Stop lever angle_02
Pump speed
r/min
1000
1000
1000
Pressure with S/T OFF
kPa
313.5
284
343
Pressure with S/T OFF
kgf/cm2
3.2
2.9
3.5
Stop lever angle_03
Pump speed
r/min
1550
1550
1550
Pressure with S/T OFF
kPa
519.5
500
539
Pressure with S/T OFF
kgf/cm2
5.3
5.1
5.5
Stop lever angle_04
Pump speed
r/min
1850
1850
1850
Pressure with S/T OFF
kPa
622.5
598
647
Pressure with S/T OFF
kgf/cm2
6.35
6.1
6.6
0000001101
Pump speed
r/min
1550
1550
1550
Timer stroke with S/T OFF
mm
1.9
1.7
2.1
Basic
*
_02
Pump speed
r/min
760
660
860
Timer stroke with S/T ON
mm
0.5
0.5
0.5
_03
Pump speed
r/min
1440
1390
1490
Timer stroke with S/T OFF
mm
0.5
0.5
0.5
_04
Pump speed
r/min
1550
1550
1550
Timer stroke with S/T OFF
mm
1.9
1.6
2.2
_05
Pump speed
r/min
1850
1850
1850
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:
Introduction
This Special Instruction is intended for the installation of the 366-9748 Injector Wiring Harness Kit . The 366-9748 Injector Wiring Harness Kit can be used to repair TPI connectors. TPI connectors can be found on HEUI injectors, variable valve actuators, and Cat Brakes.Removal of the Connector From the Wire Harness
Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-9150 Terminal Crimp Tool As 1
B 9U-6070
or Heat Gun Gp
(110V) 1
9U-6072 Heat Gun Gp (220 V) The following steps will remove the connector for an injector from the wire harness that is under the valve mechanism cover.
Illustration 1 g01035448
(1) Side "A" of the connector (2) Side "B" of the connectorNote: Side "A" or side "1" of the connector is the output signal wire from the ECM. Side"B" or side "2" of the connector is the sensor return.
Identify side "A" of the connector and identify side "B" of the connector.
Mark each wire on the wire harness before the wires are cut. Most connectors will have the label of an "A" and a "B". Some connectors may have a "1" and a "2" that is on the connector. The label with a "1" will be an "A". The label with a "2" will be a "B".
Illustration 2 g01034438
Connector that is cut from the wire harness (3) Wire on side "A" of the connector (4) Wire on side "B" of the connector
Cut wire (3) at a distance of 45 mm (1.8 inch).
Cut wire (4) at a distance of 40 mm (1.6 inch).
Illustration 3 g01034450
(5) Wire from the harness for side "B" on the connector (6) Wire from the harness for side "A" on the connectorNote: The wires on the old connector are cut to length so that the wires on the wire harness to the new connector will match up. The proper length will help in matching the harness wires to the wires on the new connector wires.
Discard the connector.Installation Procedure for the Connector
Use Tool (A) to strip the plastic off wires (5) and (6) at a distance of 5 mm (0.19 inch).
Illustration 4 g01034451
Connecting the connector to the wire harness (5) Wire from the harness for side "B" on the connector (6) Wire from the harness for side "A" on the connector (7) Heat shrink tube (8) Butt splice on wire (4) that is on side "B" of the connector (9) Butt splice on wire (3) that is on side "A" of the connector
Use the heat shrink tubes from 366-9748 Injector Wiring Harness Kit . Slide the heat shrink tubes toward the connector in order to expose the butt splices.
Take wire (5) and slide wire (5) in the butt splice (8).
Take wire (6) and slide wire (6) in the butt splice (9).
Illustration 5 g01035814
Illustration 6 g01034452
(8) Butt splice on wire (4) that is on side "B" of the connector (9) Butt splice on wire (3) that is on side "A" of the connector
Use Tool
This Special Instruction is intended for the installation of the 366-9748 Injector Wiring Harness Kit . The 366-9748 Injector Wiring Harness Kit can be used to repair TPI connectors. TPI connectors can be found on HEUI injectors, variable valve actuators, and Cat Brakes.Removal of the Connector From the Wire Harness
Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-9150 Terminal Crimp Tool As 1
B 9U-6070
or Heat Gun Gp
(110V) 1
9U-6072 Heat Gun Gp (220 V) The following steps will remove the connector for an injector from the wire harness that is under the valve mechanism cover.
Illustration 1 g01035448
(1) Side "A" of the connector (2) Side "B" of the connectorNote: Side "A" or side "1" of the connector is the output signal wire from the ECM. Side"B" or side "2" of the connector is the sensor return.
Identify side "A" of the connector and identify side "B" of the connector.
Mark each wire on the wire harness before the wires are cut. Most connectors will have the label of an "A" and a "B". Some connectors may have a "1" and a "2" that is on the connector. The label with a "1" will be an "A". The label with a "2" will be a "B".
Illustration 2 g01034438
Connector that is cut from the wire harness (3) Wire on side "A" of the connector (4) Wire on side "B" of the connector
Cut wire (3) at a distance of 45 mm (1.8 inch).
Cut wire (4) at a distance of 40 mm (1.6 inch).
Illustration 3 g01034450
(5) Wire from the harness for side "B" on the connector (6) Wire from the harness for side "A" on the connectorNote: The wires on the old connector are cut to length so that the wires on the wire harness to the new connector will match up. The proper length will help in matching the harness wires to the wires on the new connector wires.
Discard the connector.Installation Procedure for the Connector
Use Tool (A) to strip the plastic off wires (5) and (6) at a distance of 5 mm (0.19 inch).
Illustration 4 g01034451
Connecting the connector to the wire harness (5) Wire from the harness for side "B" on the connector (6) Wire from the harness for side "A" on the connector (7) Heat shrink tube (8) Butt splice on wire (4) that is on side "B" of the connector (9) Butt splice on wire (3) that is on side "A" of the connector
Use the heat shrink tubes from 366-9748 Injector Wiring Harness Kit . Slide the heat shrink tubes toward the connector in order to expose the butt splices.
Take wire (5) and slide wire (5) in the butt splice (8).
Take wire (6) and slide wire (6) in the butt splice (9).
Illustration 5 g01035814
Illustration 6 g01034452
(8) Butt splice on wire (4) that is on side "B" of the connector (9) Butt splice on wire (3) that is on side "A" of the connector
Use Tool