101421-7060 ZEXEL 9 400 614 084 BOSCH INJECTION-PUMP ASSEMBLY 9400614084 1014217060

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 084 9400614084

ZEXEL 101421-7060 1014217060

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Include in #1:

106671-2495 as _

Cross reference number

BOSCH 9 400 614 084 9400614084

ZEXEL 101421-7060 1014217060

Zexel num

Bosch num

Firm num

Name

101421-7060

9 400 614 084

ISUZU

INJECTION-PUMP ASSEMBLY
C190 * 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

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 1.75 1.7 1.8

Beginning of injection position
Drive 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 A

Rack position 11.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 32.7 31.7 33.7

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.4+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8 6.9 9.1

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Timer adjustment

Pump speed r/min 800+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 4 3.3 4.7

Timer adjustment_04

Pump speed r/min 1900

Advance angle deg. 5.3 4.6 6

Timer adjustment_05

Pump speed r/min 2250

Advance angle deg. 6.5 6 7

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Idle overrunning test possible until N1. (2)Set using the full load screw. (3)With isochronous switch ON (4)When isochronous switch OFF (5)Prevent overrunning.
----------
N1=2200r/min
----------

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=33deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(130deg)

Information:

Torque for Standard Bolts, Nuts and Taperlock Studs
The following charts give general torques for bolts, nuts, and taperlock studs. For torque specifications not included in this section, refer to Torque Specifications, SENR3130, available from your Caterpillar dealer.
Torques for Bolts and Nuts With Standard Threads
Torques for Taperlock Studs
Use these standard torque values for all fasteners, unless otherwise specified in this manual or in the Service Manual.Torque for Metric Fasteners
Be very careful never to mix metric with customary (SAE standard) fasteners. Mismatched or incorrect fasteners will cause engine damage or malfunction and may even result in personal injury.Original fasteners removed from the engine should be saved for reassembly whenever possible. If new fasteners are needed, they must be of the same size and grade as the ones that are being replaced.
Material strength identification is usually shown on the bolt head by numbers (8.8, 10.9, etc.). The following chart gives general torque values for bolts and nuts. Use these standard torque values unless otherwise specified in this publication. Metric hardware must be replaced with metric hardware. Check Parts Manual for proper replacement.Torques for Bolts and Nuts with Metric Threads
Torque for Standard Hose Clamps-Worm Drive Band Type
The following chart gives the torques for initial installation of hose clamps on new hose and for reassembly or tightening of hose clamps on existing hose. Torque for Constant Torque Hose Clamps
Due to extreme temperature changes, hose will heat set. Heat settings causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new constant torque hose clamp will help prevent these failures. A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp.
Installation
Each installation application can be different depending on the type of hose, fitting material, and anticipated expansion or contraction of the hose and fittings. A torque wrench should be used for proper installation of constant torque hose clamps. Constant torque hose clamps should be installed as follows:* To allow for maximum expansion, install clamps at 5.7 N m (50 lb in).* To allow for equal expansion and contraction, install clamps at 10.2 N m (90 lb in).* To allow for maximum contraction, install clamps at 14.1 N m (125 lb in).