101401-4541 ZEXEL 9 400 613 710 BOSCH INJECTION-PUMP ASSEMBLY 9400613710 1014014541 8970903671

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 710 9400613710

ZEXEL 101401-4541 1014014541

ISUZU 8970903671 8970903671

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101402-2004 as _

Cross reference number

BOSCH 9 400 613 710 9400613710

ZEXEL 101401-4541 1014014541

ISUZU 8970903671 8970903671

Zexel num

Bosch num

Firm num

Name

101401-4541

9 400 613 710

8970903671 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 4.1 4.05 4.15

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

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 60.9 59.3 62.5

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. 10 8.7 11.3

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)

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 60.9 59.9 61.9

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 83.7 79.7 87.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 79 79 111

Fixing the lever *

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 5 4.5 5.5

Remarks
Measure the actual speed, stop

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=G97
----------

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=440r/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:

Gauges provide indications of engine performance. Be sure they are in good working order. You can determine what is the "normal" operating range by observing the gauges over a period of time.Noticeable changes in gauge readings indicate potential gauge or engine problems. This also applies to gauge readings that have changed significantly, but are still within specifications. The cause of any sudden or significant change in gauge readings should be determined and corrected. Contact your Caterpillar dealer for assistance as needed. Oil Pressure - Indicates engine oil pressure. The oil pressure should be greatest after starting a cold engine. Oil pressure should read between 240 and 480 kPa (35 and 70 psi) when: the engine is running at rated engine speed with SAE 10W30 oil, and at operating temperature. A lower pressure is normal at low idling speed.
Engine damage can result if the engine is operated with no oil pressure gauge reading. If no pressure is indicated, stop the engine.
Jacket Water Temperature - Indicates engine coolant temperature. It should normally indicate between 77°C (170°F) and 98°C (209°F). Higher temperatures may occur under certain conditions. Maximum allowable temperature is 99°C (210°F) with the cooling system pressurized. Ammeter - Indicates the amount of charge or discharge in the battery charging circuit. Normal operation of the indicator should be slightly to the positive (right) side of "0" (zero).Check the charging system for malfunction if, during operation, the indicator is constantly to the negative (left) side of "0" (zero) or shows excessive charge. Tachometer - Indicates engine rpm (speed). The engine can be operated at high idle without damage, but should not be allowed to overspeed. Overspeeding can seriously damage your engine.
Do not exceed "bare engine high idle" rpm in any situation.
Fuel Level - Indicates fuel level in the fuel tank. The electrically operated fuel level gauge registers only when the START/STOP (ignition key) switch is ON. Fuel Pressure - Indicates fuel pressure to the injection pump. The indicator should register in the NORMAL (green) range.If the indicator moves to the OUT position or registers below 160 kPa (23 psi) when equipped with a numerical gauge, the engine will not operate properly. In most cases this is caused by a plugged fuel filter. Service Hour Meter - Indicates the total number of service meter units or clock hours the engine has operated.