104749-6160 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047496160 8941782700

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104749-6160 1047496160

ISUZU 8941782700 8941782700

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Cross reference number

ZEXEL 104749-6160 1047496160

ISUZU 8941782700 8941782700

Zexel num

Bosch num

Firm num

Name

104749-6160

8941782700 ISUZU

INJECTION-PUMP ASSEMBLY
4FC1-J *

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

Injection timing adjustment

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 36.2 35.7 36.7

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 34.7 33.2 36.2

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 36.2 35.2 37.2

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2000 2000 2000

Average injection quantity mm3/st. 32.2 30.7 33.7

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 32.6 31 34.2

Difference in delivery mm3/st. 4

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2650 2650 2650

Average injection quantity mm3/st. 11 8 14

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2650 2650 2650

Average injection quantity mm3/st. 11 8 14

Difference in delivery mm3/st. 3.5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2800 2800 2800

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 7.5 5.5 9.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 7.5 5.5 9.5

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 60

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 60

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 400 400 400

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 1250 1250 1250

Overflow quantity cm3/min 420 290 550

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Pressure kPa 431 411 451

Pressure kgf/cm2 4.4 4.2 4.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1250 1250 1250

Pressure kPa 431 411 451

Pressure kgf/cm2 4.4 4.2 4.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 2000 2000 2000

Pressure kPa 647 618 676

Pressure kgf/cm2 6.6 6.3 6.9

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2250 2250 2250

Pressure kPa 716 687 745

Pressure kgf/cm2 7.3 7 7.6

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke mm 3 2.8 3.2

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 670 570 770

Timer stroke mm 0.5 0.5 0.5

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Timer stroke mm 3 2.8 3.2

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 2000 2000 2000

Timer stroke mm 6.3 5.9 6.7

Oil temperature degC 50 48 52

_05

Pump speed r/min 2250 2250 2250

Timer stroke mm 7.4 7.1 7.8

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 29 28 30

Timer stroke TA mm 2.4 2.4 2.4

Timer stroke variation dT mm 0.6 0.4 0.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 29 28 30

Timer stroke variation dT mm 0.6 0.2 1

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 24 23 25

Timer stroke variation dT mm 1.3 0.9 1.7

Oil temperature degC 50 48 52

0000001501

Pump speed r/min 1250 1250 1250

Height m 2000 2000 2000

Atmospheric pressure difference kPa -21.9 -22.6 -21.2

Atmospheric pressure difference mmHg -164 -169 -159

Average injection quantity mm3/st. 32.6 32.6 32.6

Decrease qty mm3/st. 3.6 2.6 4.6

Decrease rate % 10 7 13

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Height m 0 0 0

Atmospheric pressure difference kPa 0 0 0

Atmospheric pressure difference mmHg 0 0 0

Decrease qty mm3/st. 0 0 0

Decrease rate % 0 0 0

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Height m 500 500 500

Atmospheric pressure difference kPa -5.9 -9.2 -2.6

Atmospheric pressure difference mmHg -44 -69 -19

Oil temperature degC 50 48 52

_04

Pump speed r/min 1250 1250 1250

Height m 2000 2000 2000

Atmospheric pressure difference kPa -21.9 -22.6 -21.2

Atmospheric pressure difference mmHg -164 -169 -159

Decrease qty mm3/st. 3.6 2.6 4.6

Decrease rate % 10 7 13

Basic *

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 1.6 1.5 1.7

Control lever angle alpha deg. 24.5 20.5 28.5

Control lever angle beta deg. 45 40 50

Test data Ex:

0000001801 MICROSWITCH ADJUSTMENT

Microswitch adjustment With the control lever 'a' from the idle position (idle stopper lever clearance L), adjust the position of the microswitch and fix it in the position where it goes OFF. After adjustment, the microswitch must not turn OFF at lever position between idle and a. Also, the microswitch lever must not contact the stopper.
----------
a=26+-1deg L=8.5+-0.2mm
----------

0000001901 W-CSD ADJUSTMENT

Adjustment of the W-CSD 1. Adjustment of the timer stroke Adjust screw (A) so that the timer stroke is the value determined from the graph. 2. Adjustment of the position of the intermediate lever. (1)Insert a shim L1 between the control lever (F) and the idle set screw (G). (2)Set intermediate lever (D) adjusting screw (E) so that adjusting screw (E) contacts control lever, and so that when intermediate lever is at right angles to pump center, intermediate lever and idle stopper bracket (H) overlap at position (J). 3. W-CSD adjustment Insert a shim L1+-0.05 between the control lever (F) and the idle set screw (G). Use adjusting screw (B) to fix the CSD lever (C) in the position where it operates the intermediate lever (D) via the rod (I). X:Temperature t (deg C) Y1:Timer stroke TA (mm) Y2:Control lever position at theta L (deg, mm) (W) Cold advancer (R) Cooling water temperature (deg C) (S) Cooling water temperature: increase direction (O) Timer piston stroke (mm) (P) Lever position (deg) (Q) lever position (mm) (M) standard point N:Pump speed
----------
L1=0.93+-0.05mm
----------
N1=500r/min a=20degC b=-20degC c=2.9+-1deg d=8+-3deg O1=0.3+-0.4mm O2=1.2+-0.6mm Q1=0.93+-0.3mm Q2=2.62+-1mm

Information:

An additional 5 hours is allowed if the harness must replaced.
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-4000 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 3.0-hour job for Group 2
An additional 10 hours is allowed if the harness must replaced.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Group Number 1
Injector Harness Inspection
-Raise the engine enclosure hood.
-Remove the air intake pipe connecting the air filter to the turbo inlet.
-Remove the valve covers.
-Inspect the injector harness wiring for contact between the harness and valve springs.
Image1.1.1
Repair
-If the harness is close to the valve spring, adjust the harness by disconnecting the injector connector rotating the connector 360 degrees and reconnecting it. This should slightly twist the wires and pull them away from the springs.
Image1.2.1
Injector Harness Replacement (If Necessary)
-If the injector harness has contacted the spring and cut the wire or exposed the wire, then replace the injector harness that is under the valve cover.
-When installing the new harness to the valve cover base make sure the tabs do not turn while torquing down the bolts(see the picture below). Keep the tabs straight, and this will help keep the wiring away from the valve springs.
Image1.3.1
Group Number 2
Injector Harness Inspection
-Remove the rear engine enclosure.
-Remove the clamp for flex boot on the air filter housing.
-Remove the rubber elbow on the inlet of the compressor side of the turbocharger.
-Remove the clamps called out in the photo for the turbocharger outlet pipe that connects to the aftercooler.
Image2.1.1
-Remove all three engine valve covers.
-Inspect the injector harness wiring for contact between the harness and valve springs.
Image2.2.1
Repair
-If the harness is close to the valve spring, adjust the harness by disconnecting the injector connector rotating the connector 360 degrees and reconnecting it. This should slightly twist the wires and pull them away from the springs.
Image2.3.1
Injector Harness Replacement (If Necessary)
-If the injector harness has contacted the spring and cut the wire or exposed the wire, then replace the injector harness that is under the valve cover.
-Remove the doors, hood, Clean Emissions Module (CEM) and mounting plate, and valve cover base.
-When installing the new harness to the valve cover base make sure the tabs do not turn while torquing down the bolts(see the picture below). Keep the tabs straight, and this will help keep the wiring away from the valve springs.
Image2.4.1
-Reinstall the previously removed hardware, and use the new 344-8311 exhaust clamp.
Image2.5.1