104741-1740 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411740

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-1740 1047411740

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Cross reference number

ZEXEL 104741-1740 1047411740

Zexel num

Bosch num

Firm num

Name

104741-1740
104741-1745

ISUZU

INJECTION-PUMP ASSEMBLY
4JB1CDT *

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 900 900 900

Boost pressure kPa 46.7 45.4 48

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 51.1 50.6 51.6

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

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. 63.3 62.8 63.8

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_03

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 36.9 32.9 40.9

Difference in delivery mm3/st. 5.5

Oil temperature degC 50 48 52

Injection timing adjustment_04

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. 40.5 38.5 42.5

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 900 900 900

Boost pressure kPa 46.7 45.4 48

Boost pressure mmHg 350 340 360

Average injection quantity mm3/st. 51.1 50.1 52.1

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_06

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. 63.3 62.3 64.3

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1900 1900 1900

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 56.7 53.2 60.2

Difference in delivery mm3/st. 5.5

Oil temperature degC 50 48 52

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. 22.2 19.2 25.2

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2400 2400 2400

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Average injection quantity mm3/st. 11

Oil temperature degC 52 50 54

Injection quantity 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. 22.2 19.2 25.2

Difference in delivery mm3/st. 4.5

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5.1 3.1 7.1

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 5.1 3.1 7.1

Difference in delivery mm3/st. 2

Oil temperature degC 48 46 50

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 *

Oil temperature degC 48 46 50

Timer adjustment_02

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

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 385 385 385

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Oil temperature degC 50 48 52

Remarks
MEASURE

Stop lever angle

Pump speed r/min 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 530 510 550

Pressure with S/T OFF kgf/cm2 5.4 5.2 5.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 550 550 550

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 78 78

Pressure with S/T OFF kgf/cm2 0.8 0.8

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1450 1450 1450

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 451 422 480

Pressure with S/T OFF kgf/cm2 4.6 4.3 4.9

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 530 510 550

Pressure with S/T OFF kgf/cm2 5.4 5.2 5.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_05

Pump speed r/min 2050 2050 2050

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Pressure with S/T OFF kPa 647 618 676

Pressure with S/T OFF kgf/cm2 6.6 6.3 6.9

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke with S/T OFF mm 5.2 5 5.4

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 550 550 550

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke with S/T ON mm 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1450 1450 1450

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke with S/T OFF mm 2.5 2.1 2.9

Oil temperature degC 50 48 52

_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke with S/T OFF mm 5.2 5 5.4

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 2050 2050 2050

Boost pressure kPa 80 78.7 81.3

Boost pressure mmHg 600 590 610

Timer stroke with S/T OFF mm 8.6 8.3 9

Oil temperature degC 52 50 54

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 4.5 4.4 4.6

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

Test data Ex:

0000001801 MICROSWITCH ADJUSTMENT

Microswitch adjustment 1. Insert a shim L mm (control lever position: a) between the control lever and the idling stopper bolt. 2. Move the microswitch in the direction of the arrow so that it turns ON. 3. Move the microswitch again in the direction of the arrow and tighten the microswitch fixing bolt where it turns OFF. Must change from ON to OFF at L1. [Lever angle b (from idle).] (A): microswitch fixing bolt
----------
L=6.0mm L1=5.6~6.4mm a=14deg b=13~15deg
----------
T=2~3N-m(0.2~0.3kgf-m) L=6.0mm

0000001901 V-FICD ADJUSTMENT

Adjustment of the V-FICD 1. Adjust the actuator rod to obtain S1. 2. Apply negative pressure P1 to the actuator and confirm the full stroke. (A) Control lever (Idling position)
----------
S1=1+1mm P1=-53.3kPa(-400mmHg)
----------
S1=1+1mm

Information:

Table 1
Required Parts
Qty Part Number Part Name Former Part Number
1 494-6233 Injector 307-3245(1)
(1) The former part number listed is for reference only and may differ.
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.
"The improved autolube injector requires a new adjustment sleeve. Follow the procedure below for the selection and adjustment of the sleeve.Changing the Metering Unit
Illustration 1 g06607746
(A) Adjustment Screw
(B) Locknut
(C) Adjustment Sleeve
Table 2
Adjustment Sleeves
Caterpillar Part Number Part Name Output cc Sleeve Color
494-6245 Sleeve 0.25 cc (0.015 cubic inch) Pink
494-6241 Sleeve 0.50 cc (0.030 cubic inch) Red
494-6242 Sleeve 0.750 cc (0.045 cubic inch) Silver
494-6243 Sleeve 1.00 cc (0.06 cubic inch) Gold
494-6244 Sleeve 1.25 cc (0.075 cubic inch) Green The automatic lubrication system offers the ability to change the amount of grease that is supplied per cycle to each grease point. Changing the grease supply amount is completed by adjusting locknut (B) or replacing adjustment sleeve (C) on the injector. See Table 2 for reference.There is a set of color-coded anodized aluminum adjustment sleeves (C) available for various lubrication dispensing amounts. Adjustment sleeves (C) provide an easy way to adjust the output of the injectors and provide a clear indication of the output setting. Adjustment sleeves (C) allow for easy system installation and preventative maintenance.Install adjustment sleeves (C) by doing the following Steps below:
Remove and discard locknut (B).
Place adjustment sleeve (C) on adjustment screw (A).
Tighten adjustment screw (A) to 6.7 N m (60 lb in).