104746-6261 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047466261 8971361032

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104746-6261 1047466261

ISUZU 8971361032 8971361032

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Cross reference number

ZEXEL 104746-6261 1047466261

ISUZU 8971361032 8971361032

Zexel num

Bosch num

Firm num

Name

104746-6261
104746-6262

8971361032 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1-T * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

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 750 750 750

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 48.7 48.2 49.2

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_02

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 67.3 66.8 67.8

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing 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. 34.1 30.1 38.1

Oil temperature degC 48 46 50

Injection timing adjustment_04

Pump speed r/min 750 750 750

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 48.7 47.7 49.7

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_05

Pump speed r/min 1150 1150 1150

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 67.5 64 71

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 67.3 66.3 68.3

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 1250 1250 1250

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 52.7 49.2 56.2

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 1900 1900 1900

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 71.8 67.8 75.8

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 28.7 25.7 31.7

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 28.7 25.7 31.7

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 52 50 54

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. 7.2 5.2 9.2

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

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. 7.2 5.2 9.2

Difference in delivery mm3/st. 2

Basic *

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. 60 60 100

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

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. 60 60 100

Oil temperature degC 48 46 50

Remarks
IDLE

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

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1900 1900 1900

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Overflow quantity cm3/min 770 640 900

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1900 1900 1900

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 618 598 638

Pressure kgf/cm2 6.3 6.1 6.5

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1900 1900 1900

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 618 598 638

Pressure kgf/cm2 6.3 6.1 6.5

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1900 1900 1900

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 4.5 4.3 4.7

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1300 1300 1300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1600 1600 1600

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 2.2 1.8 2.6

Oil temperature degC 50 48 52

_04

Pump speed r/min 1900 1900 1900

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 4.5 4.3 4.7

Basic *

Oil temperature degC 50 48 52

_05

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 7 6.7 7.4

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 3.1 3 3.2

KF dimension mm 5.5 5.4 5.6

MS dimension mm 0.7 0.6 0.8

BCS stroke mm 2.9 2.8 3

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 POTENTIOMETER ADJUSTMENT

A:Adjusting point B:Confirmation point C:Lever position Vi:Applied voltage V:Output voltage C1:Idle C2:Full speed
----------

----------
V1=1.2+-0.03V V2=7.37+-0.86V V3=10V V4=10V

Information:

USE FUEL CONSUMPTION, SERVICE HOURS OR TIME INTERVAL, WHICHEVER OCCURS FIRST. Performance of all lubrication and maintenance items in the Maintenance Schedule is the owners' responsibility.Daily
Walk-Around Inspection - Inspect for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Air Cleaner Indicator - Test Air Starting Motor (If Equipped) - Check/fill oiler bowlEvery 18 950 L (5000 gal) of Fuel or 125 Hours*
Scheduled Oil Sampling (S O S) Analysis - Obtain sample Engine Oil & Filters - Change oil and oil filter(s) Fuel System - Drain water/sediment Cooling System - Test Crankcase Breathers - Clean Engine Valve Lash (At First Oil Change Only) - Check/AdjustEvery 37 900 L (10,000 gal) of Fuel or 250 Hours*
Batteries - Clean/Check electrolyte level Belts, Hoses and Clamps - Inspect/Replace if necessary Engine Air Cleaners - Replace Engine Speed Sensors - Inspect/clean magnetic pick-upEvery 151 600 L (40,000 gal) of Fuel or 1000 Hours*
Engine Protection Devices - Inspect for proper operation (Check at least twice per year) Engine Valve Lash - Check/Adjust Turbochargers - Inspect for proper operation Engine Mounts and Crankshaft Vibration Damper - Inspect/checkEvery 341 100 L (90,000 gal) of Fuel or 2250 Hours*
Connecting Rod Bearings - ReplaceEvery 454 800 L (120,000 gal) of Fuel or 3000 Hours or Two Years*
Cooling System - Clean/Flush/replace thermostats and gasketsOverhaul Every 511 650 L (135,000 gal) of Fuel or 5400 Hours*
To minimize downtime and provide you with the lowest cost and highest value, Caterpillar recommends that the engine be overhauled before failure by scheduling an overhaul with your Caterpillar dealer. Refer to the Overhaul section in this manual on page 85. Top End Overhaul After Failure Overhaul Starting Motor - Inspect for proper operation Alternator - Inspect for proper operation Engine Speed Sensors - Inspect/clean/test*First Perform Previous Service Hour Items Caterpillar suggests that fuel consumption be used as the preferred method of determining maintenance intervals. Fuel consumption/hours will vary depending on the proper application of your engine rating and adherence to recommended maintenance procedures.