101401-4551 ZEXEL 9 400 613 711 BOSCH INJECTION-PUMP ASSEMBLY 9400613711 1014014551 8970903621

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 711 9400613711

ZEXEL 101401-4551 1014014551

ISUZU 8970903621 8970903621

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Include in #1:

101602-2192 as _

Cross reference number

BOSCH 9 400 613 711 9400613711

ZEXEL 101401-4551 1014014551

ISUZU 8970903621 8970903621

Zexel num

Bosch num

Firm num

Name

101401-4551

9 400 613 711

8970903621 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 325 325 325

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=G98
----------

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
----------
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:

Electric Starting
Startability will be improved at temperatures below 16°C (60°F) by the use of a starting aid. A jacket water (coolant) heater or other means can be used to heat the crankcase oil.Start the engine using the following procedure:1. Perform all before-starting inspections.2. If the engine is equipped with a manual control, ensure that is in the RUN position. Place the transmission in NEUTRAL (and disengage the flywheel clutch, if equipped). For Generator Sets, open the main electrical circuit breaker.2. Move throttle to approximately half engine speed to get the fuel rack to move to the FUEL ON position.3. Turn the starter switch to START (or battery disconnect switch to the ON position) or the Engine Control Switch (ECS) to MAN. START. The starting motor will crank and attempt to start the engine. At temperatures below 0°C (32°F), it may be necessary to spray starting fluid into the air cleaner inlet. Additional injections of ether may be required to start and/or achieve low idle speed.
Excessive ether can cause piston and ring damage. When using starting fluid, follow the manufacturer's instructions carefully, use it sparingly and spray it ONLY WHILE CRANKING THE ENGINE. Failure to do so could result in an explosion and/or fire and possible personal injury.Use ether for cold starting purposes only.
Do not crank the engine for more than 30 seconds.
If a warm engine fails to start within 30 seconds: release the starter switch and wait two minutes to allow the starter motor to cool before using it again.4. As soon as the engine starts, allow the engine to idle for 3 to 5 minutes, or until the water temperature gauge indicator has begun to rise. The engine should run at low idle smoothly until speed is gradually increased to high idle.
Do not increase engine speed until the oil pressure gauge indicates normal. Oil pressure should rise within 15 seconds after the engine starts. If oil pressure is not indicated on gauge within 15 seconds, stop the engine, investigate and correct the cause.
5. Allow white smoke to clear up and proceed with normal operation. Do not apply load to the engine or increase engine speed until the oil pressure gauge indicates normal. Oil pressure should raise within 15 seconds after the engine starts. For starting in cold weather, to minimize white smoke: start the engine and allow the engine to idle for 30 seconds. Increase rpm until engine speed reaches 1200 rpm. Then allow the engine to return to low idle.6. Operate the engine at low load until all systems reach operating temperature. Check all gauges during the warm-up period.Engine Starting With Jumper Cables
When boost starting an engine, follow the instructions to properly start the engine. This engine is equipped with a 12 or 24 volt starting system. Use only equal voltage for boost starting. The use of higher voltage will damage the electrical system.
Batteries give off flammable fumes that can explode.Improper jumper cable connections can cause an explosion resulting in personal injury.Prevent sparks near the batteries.