101401-4470 ZEXEL 9 400 613 703 BOSCH INJECTION-PUMP ASSEMBLY 9400613703 1014014470 8970903711

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 703 9400613703

ZEXEL 101401-4470 1014014470

ISUZU 8970903711 8970903711

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Include in #1:

101602-2181 as _

101602-2182

Cross reference number

BOSCH 9 400 613 703 9400613703

ZEXEL 101401-4470 1014014470

ISUZU 8970903711 8970903711

Zexel num

Bosch num

Firm num

Name

101401-4470

9 400 613 703

8970903711 ISUZU

INJECTION-PUMP ASSEMBLY
4HF1 * 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 134424-3920

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 3.9 3.85 3.95

Rack position
Point A R=A

Beginning of injection position
Governor 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 12.5

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 69.8 68.2 71.4

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 285 285 285

Average injection quantity mm3/st. 8.4 7.1 9.7

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.5)

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 69.8 68.8 70.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 87.3 83.3 91.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 78 78 110

Fixing the lever *

Timer adjustment

Pump speed r/min 1375--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1325

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 3.3 2.8 3.8

Timer adjustment_04

Pump speed r/min 1600--

Advance angle deg. 5 4.5 5.5

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.
----------
T1=F56
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=43deg+-5deg b=37deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg

0000001501 FICD

(A) applied negative pressure (B) Screw (c) Nut 1. Set the actuator as described below. (1)Confirm that there is clearance between the actuator lever and the speed lever. (2)Loosen the nut (C). (3)Push in the screw (B). (4)Apply P1 from the actuator (A) part. (5)Pull out the screw (B) slowly. (6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra. (7)Torque the nut (C) to T1. (8)Apply P2 several times. (9)Confirm that the actuator functions normally. (10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=515r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm

0000001601 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=1100r/min Ra=9.2+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Stamping position on the A/T outer rim (4)Pump bracket check hole position. (5)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1. (6)B.T.D.C.: aa
----------
aa=11deg
----------
a=(60deg) b=(85deg)

Information:

North America Only
When a problem arises concerning the sale, operation or service of your engine, it will normally be handled by the dealer in your area. The service facility nearest you can be located twenty-four hours a day by calling the phone number below. In U.S. and Canada: 1 (800) 447-4986.Your satisfaction is a primary concern to Caterpillar and its dealers. If you have a problem that has not been handled to your complete satisfaction, we suggest the steps that follow. Step OneDiscuss your problem with a member of management from the dealership. Step TwoWhen it appears that your problem cannot be readily resolved at the dealer level without additional assistance, use the above telephone numbers and ask to talk to a Field Service Coordinator. Regular Monday through Friday business hours are from 8:00 a.m. to 4:30 p.m. Central Standard Time (CST). Step ThreeIf you are still not satisfied, present the engine matter in writing to.Caterpillar Inc.
Manager, Customer Service, Engine Division
Mossville Bldg. A
P.O. Box 600
Peoria, Illinois 61552-0600
When contacting the Manager, Customer Service, please keep in mind that ultimately your problem will likely be resolved at the dealership, using their facilities, equipment, and personnel. Therefore, it is suggested that you follow the above steps in sequence when experiencing a problem.Outside North America
If a problem arises outside North America, and cannot be resolved at the dealer level, contact the appropriate Caterpillar subsidiary office. Central/South America (except Brazil)Caterpillar Americas Co.
100 NE Adams Street
Peoria, Illinois 61629 U.S.A.
Phone: 309-675-5876
Fax: 309-675-5384
BrazilCaterpillar Americas Co.
Edificio Brasil Interpart
Rua Guararapes, 2064 5.0 andar, cj.2
04561-004 - Sao Paulo-SP-Brazil
01.000-Sao Paulo-SP-Brazil
Phone: 011-536-3388
Fax: 011-505-1647
Far East (except Japan and Australia)Caterpillar Far East Limited
28th Floor, Sun Hung Kai Centre
30 Harbour Road
G.P.O. Box 3069
Wanchai, Hong Kong
Cable Address: CATFAREAST HKG
Telex No.: HX73305 CFEL
Phone: 5-8326333
Australia and New ZealandCaterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Telex: AA30240
Cable: CATERPILLAR MELB
Phone: (03) 339-9333
Fax: (03) 335-3366
JapanCaterpillar Mitsubishi Ltd.
3700, Tana, Sagamihara-shi
Kanagawa-ken, 229
Japan
Telex No.: 2872-261CM HAJ
Cable Address: CATERBISHICO SAGAMIHARA
Phone: Sagamihara (0427) 62-1121
Fax: (0427) 62-8542
Europe, Africa, and Middle EastCaterpillar Overseas S.A./Power Systems
YA50 76, Route de Frontenex
P.O. Box 456
1211 Geneva 6
Switzerland
Cable Address: CATOVERSEA
Telex No.: 413323
Phone: (022) 849-4444
Telecopier: (022) 849-4984
Fax: (022) 849-4544