104741-1141 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411141 8941571131

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-1141 1047411141

ISUZU 8941571131 8941571131

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Components :

0.	INJECTION-PUMP ASSEMBLY	104741-1141
1.	_
2.	FUEL INJECTION PUMP
3.	NUMBER PLATE	146638-8700
4.	_
5.	CAPSULE	146620-0120
6.	ADJUSTING DEVICE
7.	NOZZLE AND HOLDER ASSY	105118-4075
8.	Nozzle and Holder	8-94122-260-3
9.	Open Pre:MPa(Kqf/cm2)	18.1{185}
10.	NOZZLE-HOLDER	105048-3890
11.	NOZZLE	105017-1550

Scheme ###:

1.	[1]	146002-0320	PUMP HOUSING 3K D20 L R
1/6.	[1]	146601-0100	PACKING RING
6.	[1]	146100-0120	SUPPLY PUMP D20
9.	[1]	146103-0000	COVER
10.	[2]	139104-0000	FLAT-HEAD SCREW
12.	[1]	146200-0320	DRIVE SHAFT D20 L
12/1.	[1]	146200-0300	DRIVE SHAFT
12/2.	[1]	146201-0000	WOODRUFF KEY
12/3.	[2]	146202-0001	DAMPER
12/4.	[1]	146203-0000	TOOTHED GEAR
17.	[1]	146204-0000	PLAIN WASHER
20.	[1]	146210-0120	ROLLER SET MMC C=1.2
24.	[1]	146303-0000	BEARING PIN
25.	[1]	146304-0000	BEARING PIN
26.	[1]	146305-0000	CLAMPING BAND
27.	[1]	146205-0000	SLOTTED WASHER
29.	[1]	146220-0220	CAM PLATE '02'SK3074
30.	[1]	146600-0800	O-RING
31.	[1]	146300-0300	PUMP PLUNGER ' 3' 5-7.
32.	[1]	146301-0000	SLIDING PIECE
33.	[1]	146603-0700	SHIM
34.	[1]	146302-2200	COMPRESSION SPRING K=1.05
34B.	[1]	146302-2100	COMPRESSION SPRING K=1.05
34C.	[1]	146302-1700	COMPRESSION SPRING K=1.15
34D.	[1]	146302-1600	COMPRESSION SPRING K=1.15
34E.	[1]	146302-2400	COMPRESSION SPRING K=1.25
34F.	[1]	146302-2300	COMPRESSION SPRING K=1.25
35.	[1]	029998-0710	SHIM
35/1.	[1]	146603-0700	SHIM
35/1.	[1]	146603-0800	SHIM
35/1.	[1]	146603-0900	SHIM
35/1.	[1]	146603-1000	SHIM
35/1.	[1]	146603-1100	SHIM
35/1.	[1]	146603-3600	SHIM
36.	[1]	146600-0800	O-RING
37.	[1]	146310-0500	COVER 4J
38.	[2]	139106-0200	FLAT-HEAD SCREW
39.	[1]	146310-0100	COVER
40.	[2]	139106-0000	FLAT-HEAD SCREW
43.	[1]	146230-0000	SHIM
44.	[1]	146230-0100	PLAIN WASHER
45.	[1]	146231-0000	SLOTTED WASHER
47.	[2]	146233-0000	SLOTTED WASHER
48.	[2]	029998-0570	SHIM
48/1.	[1]	146603-0000	SHIM
48/1.	[1]	146603-0100	SHIM
48/1.	[1]	146603-0200	SHIM
48/1.	[1]	146603-0300	SHIM
48/1.	[1]	146603-0400	SHIM
48/1.	[1]	146603-0500	SHIM
48/1.	[1]	146603-0600	SHIM
49.	[2]	146234-0020	GUIDE PIN
50.	[1]	146402-0820	HYDRAULIC HEAD D11 2X4.0 A0
50.	[1]	146402-0820	HYDRAULIC HEAD D11 2X4.0 A0
50.	[1]	146402-0820	HYDRAULIC HEAD D11 2X4.0 A0
51.	[1]	146600-0000	O-RING
52.	[1]	029998-0330	SHIM
52/1.	[1]	146490-0000	SHIM
52/1.	[1]	146490-0100	SHIM
52/1.	[1]	146490-0200	SHIM
52/1.	[1]	146490-0300	SHIM
52/1.	[1]	146490-0400	SHIM
52/1.	[1]	146490-0500	SHIM
52/1.	[1]	146490-0600	SHIM
52/1.	[1]	146490-0700	SHIM
52/1.	[1]	146490-0800	SHIM
52/1.	[1]	146490-0900	SHIM
52/1.	[1]	146490-1000	SHIM
52/1.	[1]	146490-1100	SHIM
52/1.	[1]	146490-1200	SHIM
52/1.	[1]	146490-1300	SHIM
52/1.	[1]	146490-1400	SHIM
52/1.	[1]	146490-1500	SHIM
52/1.	[1]	146490-1600	SHIM
52/1.	[1]	146490-1700	SHIM
52/1.	[1]	146490-1800	SHIM
52/1.	[1]	146490-1900	SHIM
52/1.	[1]	146490-2000	SHIM
52/1.	[1]	146490-2100	SHIM
52/1.	[1]	146490-2200	SHIM
52/1.	[1]	146490-2300	SHIM
52/1.	[1]	146490-2400	SHIM
52/1.	[1]	146490-2500	SHIM
52/1.	[1]	146490-2600	SHIM
52/1.	[1]	146490-2700	SHIM
52/1.	[1]	146490-2800	SHIM
52/1.	[1]	146490-2900	SHIM
52/1.	[1]	146490-3000	SHIM
52/1.	[1]	146490-3100	SHIM
52/1.	[1]	146490-3200	SHIM
52/1.	[1]	146490-3300	SHIM
52/1.	[1]	146490-3400	SHIM
52/1.	[1]	146490-3500	SHIM
52/1.	[1]	146490-3600	SHIM
52/1.	[1]	146490-3700	SHIM
52/1.	[1]	146490-3800	SHIM
52/1.	[1]	146490-3900	SHIM
52/1.	[1]	146490-4000	SHIM
52/1.	[1]	146490-4100	SHIM
52/1.	[1]	146490-4200	SHIM
52/1.	[1]	146490-4300	SHIM
52/1.	[1]	146490-4400	SHIM
52/1.	[1]	146490-4500	SHIM
52/1.	[1]	146490-4600	SHIM
52/1.	[1]	146490-4700	SHIM
52/1.	[1]	146490-4800	SHIM
52/1.	[1]	146490-4900	SHIM
52/1.	[1]	146490-5000	SHIM
54.	[4]	146433-0100	GASKET
55.	[4]	146430-1420	DELIVERY-VALVE ASSEMBLY 'VE15'VR45
56.	[4]	146432-0200	COMPRESSION SPRING K=1.0
57.	[4]	146602-2300	FILLER PIECE
58.	[4]	146440-0600	FITTING L=40.5
60.	[4]	139106-0100	FLAT-HEAD SCREW
67.	[1]	146500-5120	GOVERNOR COVER
67/2.	[1]	146515-2520	CONTROL SHAFT R17.5
67/3.	[1]	146600-0100	O-RING
67/4.	[1]	139310-0200	PLAIN WASHER
67/5.	[1]	146533-9800	CONTROL LEVER
67/5B.	[1]	146533-9900	CONTROL LEVER
67/6.	[1]	014110-6440	LOCKING WASHER
67/7.	[1]	013020-6040	UNION NUT
67/13.	[1]	013020-6040	UNION NUT
67/14.	[1]	029240-6010	UNION NUT
67/15.	[1]	146526-1800	BLEEDER SCREW
67/16.	[1]	146526-0200	BLEEDER SCREW
67/18.	[1]	146587-1100	COILED SPRING
67/23.	[1]	146626-6000	BRACKET 4J
67/24.	[2]	139106-0500	FLAT-HEAD SCREW
67/25.	[2]	014110-6440	LOCKING WASHER
87.	[1]	139308-0300	PLAIN WASHER
88.	[1]	146545-0300	THREADED PIN
88B.	[1]	146545-0400	THREADED PIN
88C.	[1]	146545-0500	THREADED PIN
90.	[1]	139208-0100	UNION NUT
91.	[1]	146600-1200	O-RING
92.	[1]	146600-1000	SEAL RING
95.	[1]	146565-0120	FULCRUM LEVER I=1.9
104.	[2]	146568-0000	SLOTTED SPRING PIN
105.	[2]	026508-1140	GASKET
106.	[2]	146588-0000	COILED SPRING
107.	[1]	146569-0100	UNION NUT
108.	[1]	146570-0000	GOVERNOR SHAFT L
109.	[1]	146600-0400	O-RING
110.	[1]	029998-4130	SHIM
110/1.	[1]	146571-0000	SHIM
110/1.	[1]	146571-0100	SHIM
110/1.	[1]	146571-0200	SHIM
110/1.	[1]	146571-0300	SHIM
110/1.	[1]	146571-0400	SHIM
110/1.	[1]	146571-0500	SHIM
110/1.	[1]	146571-0600	SHIM
110/1.	[1]	146571-0700	SHIM
110/1.	[1]	146571-0800	SHIM
111.	[1]	146602-0600	PLAIN WASHER
112.	[1]	146572-0020	FLYWEIGHT ASSEMBLY
114.	[1]	146602-0500	PLAIN WASHER
115.	[1]	146575-0700	SLIDING SLEEVE '07' D0.5
116.	[1]	146576-0000	SEALING CAP
117.	[1]	029998-5460	PLUG
117/1.	[1]	146577-0000	PLUG
117/1.	[1]	146577-0100	PLUG
117/1.	[1]	146577-0200	PLUG
117/1.	[1]	146577-0300	PLUG
117/1.	[1]	146577-0400	PLUG
117/1.	[1]	146577-0500	PLUG
117/1.	[1]	146577-0600	PLUG
117/1.	[1]	146577-0700	PLUG
117/1.	[1]	146577-0800	PLUG
117/1.	[1]	146577-0900	PLUG
117/1.	[1]	146577-1000	PLUG
117/1.	[1]	146577-1100	PLUG
117/1.	[1]	146577-1200	PLUG
117/1.	[1]	146577-1300	PLUG
117/1.	[1]	146577-1400	PLUG
117/1.	[1]	146577-1500	PLUG
117/1.	[1]	146577-1600	PLUG
117/1.	[1]	146577-1700	PLUG
120.	[1]	146579-0320	RETAINING PIN
122.	[1]	146580-2000	GOVERNOR SPRING K=0.4
123.	[4]	139106-0200	FLAT-HEAD SCREW
130.	[1]	146421-0320	CAPSULE D14 DI
130/2.	[1]	026508-1140	GASKET
130/3.	[1]	146422-0300	BLEEDER SCREW
130/4.	[1]	146600-0500	O-RING
133.	[1]	146600-0600	O-RING
134.	[1]	146600-0700	O-RING
135.	[1]	146110-0620	CONTROL VALVE '06'2XD1.6K=2.
135/5.	[1]	146114-0000	SPRING WASHER
136.	[1]	146650-2420	PULLING ELECTROMAGNET ' 24'12V 4XD0
137.	[2]	029331-4010	GASKET
138.	[1]	146606-3920	PIPE S/T B2 B2 B3
145.	[1]	013020-5240	UNION NUT
146.	[1]	023500-5140	PLAIN WASHER
160.	[1]	146625-8020	PLATE
200.	[1]	146206-0100	COILED SPRING
205.	[1]	029470-4030	WOODRUFF KEY
233.	[1]	146658-3820	WIRE ' ' 12V
239.	[1]	023500-5140	PLAIN WASHER
240.	[1]	146650-1220	PULLING ELECTROMAGNET
240/8.	[1]	146600-1700	O-RING
242.	[1]	146658-0210	WIRE
243.	[1]	013020-5240	UNION NUT
245.	[3]	026512-1840	GASKET
246.	[1]	146125-0000	EYE BOLT
248.	[1]	146614-0200	SPACER BUSHING
800S.	[1]	146009-6720	PUMP HOUSING 3
800S/1.	[1]	146002-0320	PUMP HOUSING 3K D20 L R
800S/1/6.	[1]	146601-0100	PACKING RING
800S/1/6.	[1]	146601-0100	PACKING RING
804S.	[1]	146232-0320	COMPRESSION SPRING
805S.	[1]	146574-0120	PARTS SET
810S.	[1]	146600-1120	REPAIR SET
903.	[1]	146620-0120	CAPSULE
903.	[1]	146620-0120	CAPSULE
903/2.	[1]	146600-1300	O-RING
906.	[1]	146638-8700	NUMBER PLATE 4JB1-A
918.	[1]	146640-6000	NAMEPLATE

Include in #2:

104741-1141 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 104741-1141 1047411141

ISUZU 8941571131 8941571131

Zexel num

Bosch num

Firm num

Name

104741-1141
104741-1142

8941571131 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1-A *

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

Injection timing adjustment

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.6 44.1 45.1

Difference in delivery mm3/st. 3.5

Basic *

Injection timing adjustment_02

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 12.8 9.3 16.3

Injection timing adjustment_03

Pump speed r/min 1900 1900 1900

Average injection quantity mm3/st. 36 32.5 39.5

Injection timing adjustment_04

Pump speed r/min 1700 1700 1700

Average injection quantity mm3/st. 46.9 44.4 49.4

Injection timing adjustment_05

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 47 45 49

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.6 43.6 45.6

Injection timing adjustment_07

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 36.3 34.3 38.3

Injection timing adjustment_08

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 45.3 41.8 48.8

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 12.8 9.8 15.8

Difference in delivery mm3/st. 3.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 7

Governor adjustment

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 9 7 11

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 9 7 11

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 1550 1550 1550

Overflow quantity 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 333.5 304 363

Pressure with S/T OFF kgf/cm2 3.4 3.1 3.7

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 617.5 588 647

Pressure with S/T OFF kgf/cm2 6.3 6 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 790 790 790

Timer stroke with S/T ON mm 0.5 0.5 0.5

_03

Pump speed r/min 1450 1400 1500

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 1900 1900 1900

Timer stroke with S/T OFF mm 5.75 5.3 6.2

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:

Connect cable (2) to the RS-232 serial port of PC (1) .
Connect cable (2) to communication adapter (3) .
Connect cable (4) to communication adapter (3) .
Connect cable (4) to the service tool connector on the engine mounted CIP.
Turn the engine control switch to the LOCAL position or to the REMOTE position. Turn the fuel control switch to the FUEL OFF position. The engine should be OFF.If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting, RENR5910, "Electronic Service Tool Will Not Communicate With ECM".Troubleshooting
Refer to Troubleshooting, RENR5084 for more information on the following components.
Sensor faults
Injector faults
Response checks for the throttle input
Shutdown input response checksRequirements for the Electrical System
When you route the wiring, avoid acute bends and sharp edges. To protect the wiring harnesses, route the harnesses through a metal conduit. Use a rigid conduit or a use flexible conduit. A liquid tight conduit is recommended. Use proper support and alignment in order to avoid strain on the conduit.Electronic Service Tools
Caterpillar Electronic Service Tools are designed to help the service technician:
Obtain data.
Diagnose problems.
Read parameters.
Program parameters.
Calibrate sensors.The tools that are listed in Table 12 are required in order to enable a service technician to perform the electrical installation procedures and the initial start-up.Note: Other tools that are needed for measuring operating parameters such as pressure and temperature are not listed in Table 12.
Table 12
Service Tools
Pt. No. Description Functions
N/A Personal Computer (PC) This PC configuration is recommended:
Intel Pentium II 333 mHz processor
64 megabyte of RAM
4.3 GB hard drive
Drive for floppy disks (3.5 inch with 1.44 MB)
14X speed CD-ROM drive
VGA monitor or display
RS-232 port with 16550AF UART
Windows NT 4.0 (1)
Windows 95 (1)
Windows 98 (1)
Mouse
N/A Personal Computer (PC) This PC configuration has the minimum requirements:
IBM PC compatible 100 MHz processor
32 megabyte of RAM
10 MB of available hard drive space
CD-ROM drive
Drive for floppy disks (3.5 inch with 1.44 MB)
Windows NT 4.0 (1)
Windows 95 (1)
Windows 98 (1)
RS-232 port with 16550AF UART
VGA monitor or display
Mouse
"JERD2124" Software Single user license for Caterpillar Electronic Technician (Cat ET)
Use the most recent version of this software.
"JERD2129" Software Data subscription for all engines
171-4401 Communication Adapter II (1) The communication adapter is connected between the PC (ET) and the ECM.
196-0055 Serial Cable As This cable connects the PC to the 171-4401 Communication Adapter II .
7X-1414 Data Link Cable As This cable connects the service tool connector on the engine mounted junction box to the 139-4166 Adapter Cable As .
8T-8726 Adapter Cable As This breakout t is for use between the jacks and the plugs of the sensors.
151-6320 Wire Removal Tool This tool is used for the removal of pins and sockets from Deutsch connectors and AMP connectors.
1U-5804 Crimp Tool This tool is used for work with