101401-4480 ZEXEL 9 400 613 704 BOSCH INJECTION-PUMP ASSEMBLY 9400613704 1014014480 8970903631

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 704 9400613704

ZEXEL 101401-4480 1014014480

ISUZU 8970903631 8970903631

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101602-2183 as _

Cross reference number

BOSCH 9 400 613 704 9400613704

ZEXEL 101401-4480 1014014480

ISUZU 8970903631 8970903631

Zexel num

Bosch num

Firm num

Name

101401-4480

9 400 613 704

8970903631 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 12.6

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 325 325 325

Average injection quantity mm3/st. 8.8 7.5 10.1

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(12.6)

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=F85
----------

Speed control lever angle

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

----------
a=41deg+-5deg b=(37deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
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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=450r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm

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:

Engine Model Views
Typical views and attachments are shown. Because of individual applications, your engine may appear different from those illustrated.
3306B Model Views: Air Cleaner (1), Turbocharger (2), Exhaust (3), Service (Hour) Meter (4), Crankcase Breather (5), Instrument Panel (6), Lifting Eye (7), Oil Filler (8), Fuel Pressure Gauge (9), Fuel Filter (10), Fuel Priming Pump (11), Fumes Disposal Tube (12), Magnetic Pickup Location (13), Crankshaft Vibration Damper (14), Flywheel Housing (15), Oil Drain (16), Oil Level Gauge (17), and Oil Filter (18).
Standby Generator Set: Control and Power Panel (1), Optional Battery Charger Mounting Location (2), Air Cleaner (3), Solenoid (4), Fuel Priming Pump (5), Exhaust (6), Governor Control Lever (7), Crankcase Breather (8), Radiator Fill Cap (9), Circuit Breaker (10), Optional Radiator Vent Hose (11), Lifting Location (12), Starting Motor (13), Oil Drain (14), Fuel Filter (15), and Water Drain (16).
Building Service Standby (BSSB) Generator Set: Control and Power Panel (1), Optional Total Enclosure (2), Air Cleaner (3), Fuel Priming Pump (4), Governor Control Lever (5), Crankcase Breather (6), Radiator Fill Cap (7), Lifting Location (8), Starting Motor (9), Fuel Filter (10), and Oil Drain (11).
Prime Generator Set: Control and Power Panel (1), Air Inlet (2), Solenoid (3), Turbocharger (4), Exhaust (5), Governor Control Lever (6), Crankcase Breather (7), Fuel Pressure Gauge (8), Radiator Fill Cap (9), Lifting Location (10), Starting Motor (11), Fuel Priming Pump (12), Fuel Filter (13), Oil Drain (14), and Water Drain (15).Engine Information
The engines are available with direct fuel injection. The engines can be naturally aspirated, turbocharged, or turbocharged with jacket water aftercooling. The 3306B is also available turbocharged with air-to-air aftercooling (ATAAC).A full-range hydramechanical governor controls the fuel injection pump output, maintaining the engine rpm selected by the operator. Individual injection pumps (one for each cylinder) meter and pump fuel under high pressure to injection nozzles. Automatic timing advance provides the best fuel injection timing over the full range of engine speed.The cooling system consists of: * a gear driven centrifugal pump (with one thermostat which regulates the engine coolant temperature)* an oil cooler, and* a radiator (incorporating a shunt system).The engine lubricating oil, which is both cooled and filtered, is supplied by a gear-type pump. Bypass valves provide unrestricted flow of lubrication oil to the engine parts if oil viscosity is high, or if the oil cooler or the oil filter elements become plugged.Engine efficiency, efficiency of emission controls, and engine performance depend on adherence to proper operation and maintenance recommendations. Engine performance and efficiency also depend on the use of recommended fuels and lubrication oils. Follow the recommended Maintenance Schedule found in this publication, paying attention to emission related components, air cleaner, oil, oil filter, fuel and fuel filter maintenance.