104741-1402 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411402 8944528192

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-1402 1047411402

ISUZU 8944528192 8944528192

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Cross reference number

ZEXEL 104741-1402 1047411402

ISUZU 8944528192 8944528192

Zexel num

Bosch num

Firm num

Name

104741-1402
104741-1403

8944528192 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1CGT *

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 1250 1250 1250

Boost pressure kPa 46.65 45.3 48

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 49.4 48.9 49.9

Difference in delivery mm3/st. 4.5

Basic *

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 61.3 60.8 61.8

Difference in delivery mm3/st. 3.5

Basic *

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 2300 2300 2300

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 16.6 13.1 20.1

Injection timing adjustment_04

Pump speed r/min 1800 1800 1800

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 58.6 55.1 62.1

Injection timing adjustment_05

Pump speed r/min 1250 1250 1250

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 61.3 60.3 62.3

Remarks
Full

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Boost pressure kPa 46.65 45.3 48

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 49.4 48.4 50.4

Remarks
CBS

Injection timing adjustment_07

Pump speed r/min 900 900 900

Boost pressure kPa 46.65 45.3 48

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 49.5 46 53

Injection timing adjustment_08

Pump speed r/min 750 750 750

Boost pressure kPa 24 22.7 25.3

Boost pressure mmHg 180 170 190

Average injection quantity mm3/st. 39.4 35.9 42.9

Injection timing adjustment_09

Pump speed r/min 600 600 600

Boost pressure kPa 13.35 12 14.7

Boost pressure mmHg 100 90 110

Average injection quantity mm3/st. 36 32 40

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 16.6 13.6 19.6

Difference in delivery mm3/st. 4.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2600 2600 2600

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 5

Governor adjustment

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 7 5 9

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 7 5 9

Governor adjustment_03

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 80 60 100

Basic *

Speed control lever angle

Pump speed r/min 375 375 375

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1600 1600 1600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Overflow quantity cm3/min 399 270 528

Stop lever angle

Pump speed r/min 1600 1600 1600

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure kPa 490.5 471 510

Pressure kgf/cm2 5 4.8 5.2

Basic *

Stop lever angle_02

Pump speed r/min 1600 1600 1600

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure kPa 490.5 471 510

Pressure kgf/cm2 5 4.8 5.2

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure kPa 549.5 520 579

Pressure kgf/cm2 5.6 5.3 5.9

0000001101

Pump speed r/min 1600 1600 1600

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke mm 5 4.8 5.2

Basic *

_02

Pump speed r/min 1600 1600 1600

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke mm 5 4.7 5.3

_03

Pump speed r/min 1800 1800 1800

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke mm 6.2 5.8 6.6

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 5.5 5.4 5.6

MS dimension mm 0.9 0.8 1

BCS stroke mm 4.8 4.7 4.9

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 18 14 22

Control lever angle beta deg. 37 32 42

Information:

Operation Description:Power to the ECM can fail due to an open circuit in the wire, or a blown fuse. A fuse is blown out as a result of an overloaded circuit. For example, the +battery connection is shorted to ground.Test Step 1. CHECK THE ECM FOR POWER AND GROUND.At the ECM, measure the voltage from contact 1 to contact 2. Expected Result:The voltage is system voltage.Results:
OK - The voltage is system voltage. The power supply circuit to the ECM is correct. STOP
NOT OK - The voltage is not system voltage. Proceed to Test Step 2.Test Step 2. CHECK THE FUSEWhenever the machine's electronic components fail to function, check the appropriate fuse for the ECM.
Check the fuse for the ECM.Expected Result:The fuse is correct.Results:
YES - The fuse is correct. Proceed to Test Step 3.
NO - The fuse is not correct.Repair: Replace the blown fuse or reset the circuit breaker. Observe the machine for a recurrence of the problem. If the problem persists, the reason for the blown fuse must be isolated and corrected.STOPTest Step 3. CHECK THE POWER WIRE TO THE ECM.
Turn the key start switch and the disconnect switch to the OFF position.
At the fuse, connect the lead from the multimeter to wire 113-RD.
At the ECM, connect the other lead from the multimeter to connector contact 1 and measure the resistance.Expected Result:The resistance is less than 5 ohms.Results:
OK - The resistance is less than 5 ohms. The wiring circuit is correct. Proceed to Test Step 4.
NOT OK - The resistance measurement is greater than 5000 ohms. The wiring has an open circuit.Repair: Repair the wiring harness or replace the wiring harness. STOPTest Step 4. CHECK THE ECM GROUND CONNECTIONS.
The keyswitch and the disconnect switch remain in the OFF position.
At the ECM, measure the resistance from connector contact 2 to frame ground.Expected Result:The resistance is less than 5 ohms.Results:
OK - The resistance is less than 5 ohms. The ground circuit is correct. The ECM may have failed. This is unlikely. Perform this entire procedure again. If the problem remains, the ECM may need to be replaced. Contact your dealerships for possible consultation with Caterpillar. This consultation may greatly reduce repair time.STOP
NOT OK - The resistance is greater than 5000 ohms. The ground circuit has failed.Repair: The ground circuit has failed. Repair the wiring harness or replace the wiring harness.STOP