101401-4621 ZEXEL 9 400 613 716 BOSCH INJECTION-PUMP ASSEMBLY 9400613716 1014014621 8970903591

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 716 9400613716

ZEXEL 101401-4621 1014014621

ISUZU 8970903591 8970903591

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106672-3364 as _

Cross reference number

BOSCH 9 400 613 716 9400613716

ZEXEL 101401-4621 1014014621

ISUZU 8970903591 8970903591

Zexel num

Bosch num

Firm num

Name

101401-4621
101401-4870

9 400 613 716

8970903591 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 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)
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 11.6

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 67.5 65.9 69.1

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 10.2+-0. 5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 19 17.7 20.3

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 960 960 960

Average injection quantity mm3/st. 67.5 66.5 68.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.25

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 86 82 90

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 54 54 86

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.
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T1=H58
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Speed control lever angle

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

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a=40deg+-5deg b=(37deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
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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=440r/min Ra=9.1+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)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=10deg
----------
a=(60deg) b=(85deg)

Information:

You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.Before proceeding with Every 50 Hour maintenance, perform all Daily maintenance requirements.Dust Collector
Never run the engine without an air cleaner installed. Never run the engine with a damaged air cleaner. Do not use filter elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaners prevent airborne debris from entering the engine through the air inlet.
Clean
Typical two stage air cleaner. Individual applications may be different.1. Remove the air cleaner cap (1). Remove the dust collector cup (2).2. Wipe dust collector cup with a clean, dry cloth.3. Install the cup. Install and secure the cap. If equipped with a heavy duty air cleaner: refer to the Heavy Duty Air Cleaner topic in the Daily section of this manual for information about cleaning the dust collector cup.Light Duty Air Cleaner (If Equipped)
Light duty air cleaners are not serviceable (washable). Light duty air cleaners are intended for a 50 service hours of maximum use, or one year, whichever occurs first. However, engines operating in a severe environment may require more frequent air cleaner replacement.Dust conditions vary for different operating environments. Service the air cleaner at regular intervals as determined by the operating environment. Check the air cleaner service indicator (if equipped) daily.Check the air cleaner for cleanliness and damage such as rips and tears. Replace the air cleaner element at the required service interval, or more often as determined by the operating environmental dust conditions. To Replace the Light Duty Air Cleaner Element: 1. Loosen the clamp (2) fastening the air cleaner element (1) to the air inlet, and remove the dirty element and clamp.2. Install the clamp on a new element.3. Install the new element to the air inlet and tighten the clamp.