104740-1601 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047401601 8944696831

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104740-1601 1047401601

ISUZU 8944696831 8944696831

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Cross reference number

ZEXEL 104740-1601 1047401601

ISUZU 8944696831 8944696831

Zexel num

Bosch num

Firm num

Name

104740-1601
104740-1602

8944696831 ISUZU

INJECTION-PUMP ASSEMBLY
4FG1 *

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. 50.5 50 51

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. 48.5 46.5 50.5

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 50.5 49.5 51.5

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2150 2150 2150

Average injection quantity mm3/st. 40.5 38.4 42.6

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 13.9 10.9 16.9

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 13.9 10.9 16.9

Difference in delivery mm3/st. 4.5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2850 2850 2850

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 10.3 8.3 12.3

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. 10.3 8.3 12.3

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. 50 50 70

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50 50 70

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

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 451 431 471

Pressure kgf/cm2 4.6 4.4 4.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1750 1750 1750

Pressure kPa 588 568 608

Pressure kgf/cm2 6 5.8 6.2

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke mm 2 1.8 2.2

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 600 600 600

Timer stroke mm 0 0 0

Oil temperature degC 50 48 52

_03

Pump speed r/min 1010 1010 1010

Timer stroke mm 0.5 0.5

Oil temperature degC 50 48 52

_04

Pump speed r/min 1250 1250 1250

Timer stroke mm 2 1.6 2.4

Oil temperature degC 50 48 52

_05

Pump speed r/min 1750 1750 1750

Timer stroke mm 4.2 4 4.4

Basic *

Oil temperature degC 50 48 52

_06

Pump speed r/min 2150 2150 2150

Timer stroke mm 5.9 5.4 6.4

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. 38 37.5 38.5

Timer stroke TA mm 1.2 1.2 1.2

Timer stroke variation dT mm 0.8 0.6 1

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 34 33 35

Timer stroke variation dT mm 0.8 0.5 1.1

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 25 24 26

Timer stroke variation dT mm 1.6 1.1 2.1

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 0.9 0.8 1

Control lever angle alpha deg. -2 -6 2

Control lever angle beta deg. 38 33 43

Test data Ex:

0000001801 A/T PLATE ADJUSTMENT

A/T plate adjustment 1. Turn (beta) so that the control lever (C/L) moves from the idle position (B) to the full speed position (C) 2. When angle beta is e, adjust A/T plate (D) so that wire stroke L3 is secured between (A) and (B), then fix.
----------
L3=33+-1mm e=38+-5deg
----------
L1=95.5mm L2=109.5mm L3=33+-1mm

Information:

start by:a) remove turbocharger1. Make a mark on compressor housing (1), cartridge assembly (3) and turbine housing for correct installation. 2. Loosen clamp assemblies (2). Remove compressor housing (1) and cartridge assembly (3) from the turbine housing.3. Put the cartridge assembly in tooling (A).
When nut (5) is loosened, do not put a side force on the shaft.
4. Remove nut (5) and O-ring seal (6). 5. Put the cartridge assembly in a press. Remove the shaft assembly from compressor wheel (7) and cartridge (8). 6. Remove seal ring (10) and shroud (11) from shaft assembly (9).7. Use tooling (B) to remove snap ring (12).
Do not cause damage to insert (13) when it is removed.
8. Install screwdrivers as shown. Carefully lift insert (13) out of the cartridge assembly. 9. Remove sleeve (14) and O-ring seal (15) from the insert. 10. Remove two seal rings (16) from the sleeve.11. Remove deflector (17) from the cartridge assembly. 12. Remove ring (18). 13. Remove sleeve (19) from the cartridge assembly. Make an identification of the position of bearing (20) for assembly purposes.14. Remove bearing (20) from the cartridge assembly. 15. Remove ring (21). 16. Use tooling (C) to remove snap ring (23). Remove sleeve (22) and the lower snap ring. 17. Turn the cartridge housing over. Remove snap ring (26) with tooling (C).18. Remove bearing (25), sleeve (24) and the lower snap ring. Assemble Turbocharger (Schwitzer 4TF555)
Make sure all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Put clean engine oil on all parts of the cartridge assembly. 1. Install snap ring (4) with tooling (A) in cartridge housing (1).2. Put sleeve (3) and bearing (2) in position. Install snap ring (5) with tooling (A).3. Turn the cartridge housing over. Install snap ring (8) with tooling (A). 4. Install sleeve (6) and snap ring (7).5. Put ring (10) in position in the cartridge housing. 6. Install bearing (9) with grooved side up. Make an alignment of the dowel in the housing with the hole on the right side of the notch.7. Put sleeve (12) in position. Install ring (11). 8. Put deflector (13) in position as shown. 9. Put two seal rings (15) in position on sleeve (14).10. Put O-ring seal (17) in position on insert (16). 11. Install sleeve (14) in insert (16).12. Install insert assembly (18) with the flange down in the cartridge housing. 13. Put O-ring seal (20) in position.14. Install snap ring (19) with tooling (B). 15. Put shaft assembly (22) in tooling (D). Put 6V2055 High Vacuum Grease in the groove for seal ring (23) at assembly to one half or more of the depth of the groove all the way around the groove. 16. Put seal ring (23) in position on the shaft assembly.17. Install shround (21) on the shaft assembly (22).18. Lightly oil the wheel face that will be under the nut. Put compressor wheel (24) in position.
Do not put a side force on the shaft