101401-4421 ZEXEL 9 400 613 351 BOSCH INJECTION-PUMP ASSEMBLY 9400613351 1014014421 8970857011

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 351 9400613351

ZEXEL 101401-4421 1014014421

ISUZU 8970857011 8970857011

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Buy INJECTION-PUMP ASSEMBLY 101401-4421 zexel genuine, new aftermarket engine parts with delivery

Service parts 101401-4421 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8910

3. GOVERNOR 105931-9681

4. SUPPLY PUMP 105210-6130

5. AUTOM. ADVANCE MECHANIS 105671-0191

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6241

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3501

14. NOZZLE 105017-2060

15. NOZZLE SET

Include in #1:

101401-4421 as INJECTION-PUMP ASSEMBLY

101602-2152 as _

Cross reference number

BOSCH 9 400 613 351 9400613351

ZEXEL 101401-4421 1014014421

ISUZU 8970857011 8970857011

Zexel num

Bosch num

Firm num

Name

101401-4421

9 400 613 351

8970857011 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1-T K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.4 3.35 3.45

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 11.6

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 72.1 70.5 73.7

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 12.1 10.8 13.4

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 72.1 71.1 73.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 82.6 79.4 85.8

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 53.6 49.6 57.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position (R1+0.1)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 76.1 72.9 79.3

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 116 116 124

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1000+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=C52
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=3.5deg+-5deg b=27deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=45deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(11.6)mm Rb=(R1-0.15)mm Pa=79.4+-2.7kPa(596+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=72.1+-1cm3/1000st Q2=69.8+-1.6cm3/1000st

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(100deg)

Information:

TECHNICAL INFORMATION BULLETIN JAN. 15th, 2003
EXCAVATORS
WHEEL LOADERS
ENGINES 322C: (EMR, MAR);
325C: (CRB, CSJ, JLC, JLD, DTF)
950G II: (AYL, AYB);
962G II: (AYE, BAB)
3126B: (BMA)
Component Code(s) 1408SUBJECT: A NEW INJECTION ACTUATION PRESSURE CONTROL VALVE CONNECTOR INCREASES ENGINE OPERATION
PROBLEM:
The injection actuation pressure (IAP) control valve connector may have been assembled incorrectly on some 3126B engine harnesses. This can lead to intermittent engine operation or can cause the engine to stop.
SOLUTION:
If your machine exhibits symptoms of intermittent engine operation or abruptly stopping, the IAP control valve connector should be disconnected from the machine, examined for solenoid contact problems and re-installed using a correct procedure.
Procedure for installing the IAP control valve connector
This procedure will describe how to properly install the 232-4367 Harness.
Required Parts
Qty Part Number Description
1 232-4367 Harness
Procure the part that is listed in the table.
Illustration 1. Left Side of a 3126B Engine on a D6N.
(1) IAP Control Valve
(2) IAP Control Valve Connector
Note: Illustration 1 is from a D6N that is equipped with a 3126B for photographical purposes. The location of the IAP Control Valve is the same for your machine.
Disconnect the IAP control valve connector (2) from the IAP Control Valve (1). See Illustration 1.
Cut the two wires directly behind the connector.
Using wire strippers, strip the ends of the two wires.
Install the 232-4367 Harness, by crimping the stripped wires inside the splice.
Note: Take care to connect the pink wire to the pink wire on one hand and the purple wire to the purple wire on the other hand.
Heat both heat shrinkable tubes in order to insulate both the splices.
Reconnect the repaired harness to the IAP Control Valve (1).
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ALL RIGHTS RESERVED