104741-1100 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411100 8941403871

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-1100 1047411100

ISUZU 8941403871 8941403871

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Cross reference number

ZEXEL 104741-1100 1047411100

ISUZU 8941403871 8941403871

Zexel num

Bosch num

Firm num

Name

104741-1100
104741-1102

8941403871 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1BG *

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)
Left L

Injection timing adjustment

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 47.2 46.7 47.7

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 41.1 37.6 44.6

Difference in delivery mm3/st. 5

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 42.1 40.1 44.1

Difference in delivery mm3/st. 5

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 47.2 46.2 48.2

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 48.1 46.1 50.1

Difference in delivery mm3/st. 6

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 47.1 44.6 49.6

Difference in delivery mm3/st. 5.5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 13 10 16

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 5

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 13 10 16

Difference in delivery mm3/st. 4

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 8 6 10

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 8 6 10

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 75 115

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 75 115

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 390 390 390

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 1500 1500 1500

Overflow quantity cm3/min 530 400 660

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1500 1500 1500

Pressure with S/T OFF kPa 510 490 530

Pressure with S/T OFF kgf/cm2 5.2 5 5.4

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_02

Pump speed r/min 1500 1500 1500

Pressure with S/T OFF kPa 510 490 530

Pressure with S/T OFF kgf/cm2 5.2 5 5.4

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1500 1500 1500

Timer stroke with S/T OFF mm 2.3 2.1 2.5

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 600 600 600

Timer stroke with S/T ON mm 0.5 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1270 1270 1270

Timer stroke with S/T OFF mm 0.5 0.5 0.5

Oil temperature degC 50 48 52

_04

Pump speed r/min 1500 1500 1500

Timer stroke with S/T OFF mm 2.3 2.1 2.5

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 1950 1950 1950

Timer stroke with S/T OFF mm 5.7 5.2 6.1

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001501

Pump speed r/min 1000 1000 1000

Height m 2000 2000 2000

Atmospheric pressure difference kPa -21.9 -21.9 -21.9

Atmospheric pressure difference mmHg -164 -164 -164

Average injection quantity mm3/st. 42.5 42.5 42.5

Decrease qty mm3/st. 4.7 4.7 4.7

Decrease rate % 10 7 13

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 1000 1000

Height m 0 0 0

Atmospheric pressure difference kPa 0 0 0

Atmospheric pressure difference mmHg 0 0 0

Decrease qty mm3/st. 0 0 0

Decrease rate % 0 0 0

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Height m 500 500 500

Atmospheric pressure difference kPa -5.9 -9.2 -2.6

Atmospheric pressure difference mmHg -44 -46.5 -41.5

Oil temperature degC 50 48 52

Remarks
Point of inflection

_04

Pump speed r/min 1000 1000 1000

Height m 2000 2000 2000

Atmospheric pressure difference kPa -21.9 -21.9 -21.9

Atmospheric pressure difference mmHg -164 -164 -164

Decrease qty mm3/st. -4.7 -4.7 -4.7

Decrease rate % -10 -13 -7

Oil temperature degC 50 48 52

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:

Safety Section
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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00104545Prevent the machine from movement. Park the machine on a level surface.Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.Required Parts
Table 1 contains the parts needed to complete the installation of the new DEF filter.Note: Only one DEF filter group is required per engine. Use Table 2 to determine which filter is the appropriate filter for each DEF header. Illustration 2 shows the location of the DEF header part number.
Table 1
Part Number Part Description Qty
378-3187 Diesel Exhaust Fluid Filter Gp 1
423-3251 Connector 1
391-5262 Gasket 1
425-0385 Filter As 1
452-6055 Filter Base As 1
453-1604(1) Diesel Exhaust Fluid Filter Gp 1
453-1605(1) Diesel Exhaust Fluid Filter Gp 1
453-1606(1) Diesel Exhaust Fluid Filter Gp 1
(1) Use Table 2 to choose the correct part that corresponds to the DEF header
Illustration 2 g03745839
(1) Location of DEF heater part number
Table 2
DEF Heater Part Number Required DEF Filter
434-3241 453-1604
434-3242 453-1605
434-3243 453-1606 Installation Procedure
Ensure that the area around the DEF heater is clean and free from debris.
Remove manifold DEF heater from DEF tank. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install for the correct procedure.
Illustration 3 g06013988
Typical example
Position filter base assembly (3) to DEF heater (2). Install screws (1) to filter base assembly (3). Tighten the self-tapping screws (1) securely.Note: Each half of the adapter has two small locking tabs that secure to the bottom side of the DEF heater.
Remove existing filter from the pickup pipe on manifold DEF heater. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install for the correct procedure.
Install a new filter to the pickup pipe on manifold DEF heater. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install for the correct procedure.
Illustration 4 g06013992
Typical example
Position the correct DEF filter (5) to the filter base assembly (3). Install band clamp (4). Tighten the band clamp to a torque