101472-0090 ZEXEL 9 400 614 191 BOSCH INJECTION-PUMP ASSEMBLY 9400614191 1014720090 8970316330

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 191 9400614191

ZEXEL 101472-0090 1014720090

ISUZU 8970316330 8970316330

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Service parts 101472-0090 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101047-9030

3. GOVERNOR 105419-0670

4. SUPPLY PUMP 105220-5850

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156635-6320

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105151-1451

11. Nozzle and Holder 5-15300-039-1

12. Open Pre:MPa(Kqf/cm2) 11.8{120}

13. NOZZLE-HOLDER 105081-3141

14. NOZZLE

105000-1650

15. NOZZLE SET

Include in #1:

101461-0260 as _

101472-0090 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 614 191 9400614191

ZEXEL 101472-0090 1014720090

ISUZU 8970316330 8970316330

Zexel num

Bosch num

Firm num

Name

101472-0090
101472-0110

9 400 614 191

8970316330 ISUZU

INJECTION-PUMP ASSEMBLY
C240 * 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 2.25 2.2 2.3

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 9.6

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 27.3 26.3 28.3

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 10

Pump speed r/min 725 725 725

Average injection quantity mm3/st. 34.6 33.1 36.1

Max. variation between cylinders % 0 -4.5 4.5

Fixing the lever *

Injection quantity adjustment_03

Adjusting point -

Rack position 8.9+-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.

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 77.2 72.2 82.2

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Idle sub spring setting: L1.
----------
K=15 L1=6-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Pump speed = bb (at delivery) (3)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=5deg+-5deg b=4deg+-5deg c=19deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=36.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Gear mark Z for the No. 4 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(60deg)

Information:

Illustration 6 g06375966
Current hose routing
(E) 3U-2752 Clip
Illustration 7 g06375968
(D3) 32.31 mm (1.272 inch)
(D4) 80.00 mm (3.150 inch)
(1) 178-7023 Boss
Illustration 8 g06375967
New hose routing
(1) 178-7023 Boss
(2) 420-5299 Clip
Remove clip (E) and install boss (1) per the dimensions and secure the hose using two double clips (2), as shown in Illustration 6, Illustration 7, and Illustration 8.Changes to CEM Line Routing for 730C2, 730C2 EJ, 730, and 735 Articulated Trucks
Illustration 9 g06376002
Current hose routing
(F) 421-9627 Bracket As
(G) 3U-2752 Clip
(H) 7K-1181 Cable Strap
Remove bracket assembly (F), clips (G), strap cable (H), and other mounting hardware, as shown in Illustration 9.
Illustration 10 g06376255
New hose routing
(2) 420-5299 Clip
Install two double clips (2) as shown in Illustration 10.Note: The hose routing simplifies the installation and provides additional clearance to the oil gallery on the right-hand side of the machine.Changes to DEF cooling Lines Routing (To/From Tank) for all High Regulated Countries (HRC) Machines
Illustration 11 g06376256
Current hose routing
(J) 312-0288 Clamp
Illustration 12 g06376257
New hose routing
(3) 520-7003 ClampRemove old clamps (J) and replace with the new clamps (3), as shown in Illustration 11 and Illustration 12.Changes to DEF Cooling Lines Routing (To Pump- Both ends) for all HRC Machines
Illustration 13 g06376263
Current clamp
(J) 312-0288 Clamp
Illustration 14 g06376264
New clamp
(3) 520-7003 Clamp
Illustration 15 g06376266
Current clamp
(J) 312-0288 Clamp
Illustration 16 g06376267
New clamp
(3) 520-7003 ClampRemove old clamps (J) and replace with the new clamps (3), as shown in Illustration 13, Illustration 14, Illustration 15, and Illustration 16.Changes to DEF Cooling Lines (From Pump- Both ends) Routing for all HRC Machines
Illustration 17 g06376285
Current clamp
(K) 433-0933 Clamp
Illustration 18 g06376288
New clamp
(4) 520-7002 ClampRemove existing clamps (K) and replace with the new clamps (4), as shown in Illustration 17 and Illustration 18.