Information injection-pump assembly
ZEXEL
104741-1451
1047411451
ISUZU
8944378621
8944378621
Rating:
Cross reference number
ZEXEL
104741-1451
1047411451
ISUZU
8944378621
8944378621
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)
Left L
Left L
Injection timing adjustment
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
32.3
31.8
32.8
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_02
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
33.5
30
37
Oil temperature
degC
50
48
52
Injection timing adjustment_03
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
34.5
31.7
37.3
Oil temperature
degC
50
48
52
Injection timing adjustment_04
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
32.3
31.3
33.3
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
Injection timing adjustment_05
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
31.8
28.8
34.8
Oil temperature
degC
50
48
52
Injection quantity adjustment
Pump speed
r/min
1430
1430
1430
Average injection quantity
mm3/st.
13.7
10.7
16.7
Difference in delivery
mm3/st.
4.5
Basic
*
Oil temperature
degC
50
48
52
Injection quantity adjustment_02
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
6
Oil temperature
degC
50
48
52
Injection quantity adjustment_03
Pump speed
r/min
1430
1430
1430
Average injection quantity
mm3/st.
13.7
10.7
16.7
Difference in delivery
mm3/st.
4.5
Oil temperature
degC
50
48
52
Governor adjustment
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
9.3
7.3
11.3
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
9.3
7.3
11.3
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.
60
50
70
Basic
*
Oil temperature
degC
48
46
50
Remarks
Full
Full
Timer adjustment_02
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
50
50
Oil temperature
degC
48
46
50
Speed control lever angle
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
0000000901
Pump speed
r/min
800
800
800
Overflow quantity
cm3/min
300
170
430
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
800
800
800
Pressure
kPa
265
245
285
Pressure
kgf/cm2
2.7
2.5
2.9
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_02
Pump speed
r/min
600
600
600
Pressure
kPa
196
167
225
Pressure
kgf/cm2
2
1.7
2.3
Oil temperature
degC
50
48
52
Stop lever angle_03
Pump speed
r/min
800
800
800
Pressure
kPa
265
245
285
Pressure
kgf/cm2
2.7
2.5
2.9
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_04
Pump speed
r/min
1100
1100
1100
Pressure
kPa
382
353
411
Pressure
kgf/cm2
3.9
3.6
4.2
Oil temperature
degC
50
48
52
0000001101
Pump speed
r/min
800
800
800
Timer stroke
mm
1.9
1.7
2.1
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
600
600
600
Timer stroke
mm
0.5
0.1
0.9
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
800
800
800
Timer stroke
mm
1.9
1.7
2.1
Basic
*
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
1100
1100
1100
Timer stroke
mm
4.1
3.8
4.5
Oil temperature
degC
50
48
52
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
1.6
1.5
1.7
Pre-stroke
mm
0.45
0.43
0.47
Control lever angle alpha
deg.
20
16
24
Control lever angle beta
deg.
37
32
42
Information:
Introduction
There have been instances of issues with DEF pumps. After analysis, the cause of the issues has been found as contamination with hydrocarbons.Note: Diesel fuel is an example of a hydrocarbon.The DEF filter is equipped with a compensator located in the center of the filter assembly. If the compensator comes into contact with hydrocarbons, the compensator will swell and is designed to block the filter assembly and protect the DEF pump.Solution
The following procedure is designed to diagnose if the DEF pump has been contaminated with hydrocarbons.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Ensure that the engine is stopped before any servicing or repair is performed. The Diesel Exhaust Fluid (DEF) system must have completed a proper shutdown. Service on the DEF pump prior to completion of a proper shutdown can result in DEF spray and spillage.
Do not turn off the battery disconnect switch until the indicator lamp has turned off. If the switch is turned off when the indicator lamp is illuminated, the Diesel Exhaust Fluid (DEF) system may not shut down properly. If the DEF system does not shut down properly, DEF could freeze and damage the pump and lines.
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, "Cat Dealer Service Tool Catalog" or refer to Special Publication, PECJ0003, "Cat Shop Supplies and Tools Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Note: Clean water should be used to wash spilled DEF off machine components and surfaces.Note: Wear gloves when handling the DEF filter.
Illustration 1 g06278274
(1) Protective cover
Remove protective cover (1).
Illustration 2 g06278289
(2) DEF filter cap
Use a suitable tool to remove DEF filter cap (2).
Illustration 3 g06278325
(3) Compensator
With the filter installed in the DEF pump, carefully remove compensator (3).
Illustration 4 g06614423
(A) 85 mm (3.3 inch)
(B) 17 mm (0.7 inch)
Check the measurements of compensator (3). Check if the measurements are greater than specified in Illustration 4. This condition indicates that the DEF pump is contaminated with hydrocarbons.
If the measurements indicate contamination, replace the DEF pump filter. Refer to Operation and Maintenance Manual, Diesel Exhaust Fluid Filter - Replace.Flush the DEF tank. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Tank - Flush.
If the measurements are within the specification, continue to follow the appropriate troubleshooting procedure to determine if the DEF pump has a fault.
There have been instances of issues with DEF pumps. After analysis, the cause of the issues has been found as contamination with hydrocarbons.Note: Diesel fuel is an example of a hydrocarbon.The DEF filter is equipped with a compensator located in the center of the filter assembly. If the compensator comes into contact with hydrocarbons, the compensator will swell and is designed to block the filter assembly and protect the DEF pump.Solution
The following procedure is designed to diagnose if the DEF pump has been contaminated with hydrocarbons.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Ensure that the engine is stopped before any servicing or repair is performed. The Diesel Exhaust Fluid (DEF) system must have completed a proper shutdown. Service on the DEF pump prior to completion of a proper shutdown can result in DEF spray and spillage.
Do not turn off the battery disconnect switch until the indicator lamp has turned off. If the switch is turned off when the indicator lamp is illuminated, the Diesel Exhaust Fluid (DEF) system may not shut down properly. If the DEF system does not shut down properly, DEF could freeze and damage the pump and lines.
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, "Cat Dealer Service Tool Catalog" or refer to Special Publication, PECJ0003, "Cat Shop Supplies and Tools Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Note: Clean water should be used to wash spilled DEF off machine components and surfaces.Note: Wear gloves when handling the DEF filter.
Illustration 1 g06278274
(1) Protective cover
Remove protective cover (1).
Illustration 2 g06278289
(2) DEF filter cap
Use a suitable tool to remove DEF filter cap (2).
Illustration 3 g06278325
(3) Compensator
With the filter installed in the DEF pump, carefully remove compensator (3).
Illustration 4 g06614423
(A) 85 mm (3.3 inch)
(B) 17 mm (0.7 inch)
Check the measurements of compensator (3). Check if the measurements are greater than specified in Illustration 4. This condition indicates that the DEF pump is contaminated with hydrocarbons.
If the measurements indicate contamination, replace the DEF pump filter. Refer to Operation and Maintenance Manual, Diesel Exhaust Fluid Filter - Replace.Flush the DEF tank. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Tank - Flush.
If the measurements are within the specification, continue to follow the appropriate troubleshooting procedure to determine if the DEF pump has a fault.