104741-1082 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047411082 8941397411

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104741-1082 1047411082

ISUZU 8941397411 8941397411

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Cross reference number

ZEXEL 104741-1082 1047411082

ISUZU 8941397411 8941397411

Zexel num

Bosch num

Firm num

Name

104741-1082
104741-1084

8941397411 ISUZU

INJECTION-PUMP ASSEMBLY
4JA1-AG *

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)
Left L

(Solenoid timer adjustment condition) OFF

Injection timing adjustment

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 39.5 39 40

Difference in delivery mm3/st. 3

Basic *

Injection timing adjustment_02

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 16.1 12.6 19.6

Injection timing adjustment_03

Pump speed r/min 2000 2000 2000

Average injection quantity mm3/st. 32.7 28.2 37.2

Injection timing adjustment_04

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 38.9 35.9 41.9

Injection timing adjustment_05

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 42.2 39.2 45.2

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 39.5 38.5 40.5

Injection timing adjustment_07

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 35.1 32.6 37.6

Injection timing adjustment_08

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 36.1 32.1 40.1

Injection quantity adjustment

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 16.1 13.1 19.1

Difference in delivery mm3/st. 4.5

Basic *

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 5

Governor adjustment

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 7.5 5.5 9.5

Difference in delivery mm3/st. 2

Basic *

Governor adjustment_02

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 7.5 5.5 9.5

Governor adjustment_03

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 3

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 75 105

Basic *

Speed control lever angle

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 0 0 0

Remarks
Magnet OFF

0000000901

Pump speed r/min 1500 1500 1500

Overflow quantity cm3/min 519 390 648

Stop lever angle

Pump speed r/min 1500 1500 1500

Pressure kPa 519.5 500 539

Pressure kgf/cm2 5.3 5.1 5.5

Basic *

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Pressure kPa 323.5 294 353

Pressure kgf/cm2 3.3 3 3.6

Stop lever angle_03

Pump speed r/min 1500 1500 1500

Pressure kPa 519.5 500 539

Pressure kgf/cm2 5.3 5.1 5.5

Stop lever angle_04

Pump speed r/min 1950 1950 1950

Pressure kPa 666.5 637 696

Pressure kgf/cm2 6.8 6.5 7.1

0000001101

Pump speed r/min 1500 1500 1500

Timer stroke mm 2.3 2.1 2.5

Basic *

_02

Pump speed r/min 550 450 650

Timer stroke with S/T ON mm 0.5 0.5 0.5

_03

Pump speed r/min 1250 1200 1300

Timer stroke with S/T OFF mm 0.5 0.5 0.5

_04

Pump speed r/min 1500 1500 1500

Timer stroke with S/T OFF mm 2.3 2 2.6

_05

Pump speed r/min 1950 1950 1950

Timer stroke with S/T OFF mm 5.7 5.3 6.1

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 0.9 1.1

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

Information:

Illustration 4 g06005614
(A) Hydraulic tank drain
Drain the hydraulic tank. Refer to Illustration 4.Note: After draining, if a significant number of metal particles are visible in the tank, contact BCP STTT support through the DSN for guidance before proceeding further.
Drain the hydraulic cylinders.
Disconnect and drain the lines at all cylinders.
Retract and extend the cylinder rods to evacuate cylinders.
Illustration 5 g06005620
(B) Inlet lines
(C) Outlet lines
Drain the hydraulic oil cooler. Refer to Illustration 5.
Remove inlet and outlet lines at cooler.
Drain the cooler and the lines.Note: Ensure that the cooler has been drained.
Illustration 6 g06005623
(D) Case plug
Drain the hystat pumps. Refer to Illustration 6.
Remove case plug (D) on the rear right side of the pump.
Drain pumps and suction remaining oil from pump housing.Note: Ensure that the pump case has been drained.
Illustration 7 g06005628
(E) Parking brake lines
Drain the parking brake lines. Refer to Illustration 7.
Disconnect and drain the parking brake line (E) at the bottom of the pumps.
Disconnect and drain the right-hand brake line (E) connection.
Illustration 8 g06005631
(F) Case drain lines and hystat motors
Drain the drive motors. Refer to Illustration 8.
Disconnect the case drain lines at the hystat motors.Note: Ensure that the motor cases have been drained.
Illustration 9 g06005637
Standard Machine
(G) Hydraulic filter
Illustration 10 g06005640
Winch Machine
(G) Hydraulic filter
(H) Winch hydraulic filter
Drain the hydraulic filters. Refer to Illustrations 9 and 10.
Replace the standard and winch (if equipped) filters with each drain cycle.
Check filters for metal particles.
Refill the hydraulic system, repeat Steps 2 through 8, running and warming the hydraulic oil between drain, fill, and filter change cycles. Cycle all cylinders and travel circuits after every fill cycle to achieve full circulation throughout the hydraulic and power train systems with the new oil. Perform SOS check after each run cycle and follow standard SOS guidelines, specifically checking for DEF.Note: Typically takes 5 to 6 drain/refill cycles to clean the hydraulic system and get a clean SOS sample. Clean oil will be red and transparent or clear / light yellow and transparent. If there is any milky appearance to the color, repeat Steps 2 through 9.
Confirm that charge pressure can be set and maintained to specification, especially at pump stall.
Recalibrate the hystat pumps and drive motors, ensuring that calibration is successfully completed. Confirm that the hystat pump pressure can be adjusted to the correct specificationNote: Refer to Testing and Adjusting, UENR4089, "D3K2, D4K2, and D5K2 Track-Type Tractor Systems" for the correct procedure and specification.
Illustration 11 g06005642
(1) 484-5902 Diesel Exhaust Fluid (DEF) film(U.S.)(Shown)
(1A) 393-2614 Diesel Exhaust Fluid (DEF) film(International)
(2) 484-5903 Hydraulic oil film
(3) 430-3036 Diesel Exhaust Fluid (DEF) Gauge (Inst) film(Inside Door)
Illustration 12 g06237577
(1) 484-5902 Diesel Exhaust Fluid (DEF) film
(1A) 393-2614 Diesel Exhaust Fluid (DEF) film (International)
(2) 484-5903 Hydraulic oil film
Illustration 13 g06166475
(3) 430-3036 Diesel Exhaust Fluid (DEF) Gauge (Inst) film
New extra DEF (1), hydraulic oil (2), and DEF gauge instruction (3) films will be used in production. Refer to Table 2 for the affected machines that require the new films. For the film locations, refer to Illustrations 11, 12, and 13.Note: Adding these stickers to reduce chances of a recurrence of this issue is recommended.Note: Refer