101401-0861 ZEXEL 9 400 613 583 BOSCH INJECTION-PUMP ASSEMBLY 9400613583 1014010861 8943263431

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 583 9400613583

ZEXEL 101401-0861 1014010861

ISUZU 8943263431 8943263431

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Buy INJECTION-PUMP ASSEMBLY 101401-0861 zexel genuine, new aftermarket engine parts with delivery

Service parts 101401-0861 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8590

3. GOVERNOR 105931-5761

4. SUPPLY PUMP 105210-6130

5. AUTOM. ADVANCE MECHANIS 105671-0061

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4321

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6(220)

13. NOZZLE-HOLDER 105048-5011

14. NOZZLE 105017-1660

15. NOZZLE SET

Include in #1:

101401-0861 as INJECTION-PUMP ASSEMBLY

107691-3103 as _

Cross reference number

BOSCH 9 400 613 583 9400613583

ZEXEL 101401-0861 1014010861

ISUZU 8943263431 8943263431

Zexel num

Bosch num

Firm num

Name

101401-0861

9 400 613 583

8943263431 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1 K 14BC INJECTION PUMP ASSY PE4A,5A, PE

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.6 3.55 3.65

Rack position
After adjusting injection quantity. R=A

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 -

Rack position 11.6

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 65.5 63.9 67.1

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 9.5+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9.4 8.1 10.7

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 950 950 950

Average injection quantity mm3/st. 65.5 64.5 66.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(11.6)

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 73.7 70.5 76.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 48.2 45 51.4

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 90 90 98

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1100--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1050

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 5 4 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. (3)RACK LIMIT (4)At delivery (at R = A, N = N1)
----------
T1=D41 N1=100r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)Set the idle side stopper bolt at rack position = aa (at delivery).
----------
aa=R1(11.6)mm
----------
a=(2.5deg) b=43deg+-3deg c=2.5deg+-5deg

Stop lever angle

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

----------
a=45deg+-5deg b=29deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(11.6)mm Rb=(R1-0.1)mm Pa=79.4+-2.7kPa(596+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=65.5+-1cm3/1000st Q2=64.9+-1.6cm3/1000st

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(90deg)

Information:

Disassembly and Reassembly of General Parts
Oil seals
When driving oil seals into place, follow the instructions below: Driving Seals into Housing:(a) Place the seal lip correctly. Make sure it is not damaged.(b) Before driving a seal into place, apply a light coat of grease to the periphery of the seal that fits into the housing.(c) Use a driving tool like the one shown in the illustration that is specifically designed for the purpose. The tool can properly guide the lip and hold evenly the top of the seal when it is tapped, so it allows the seal to be driven straight down. Do not use hammers on bare seals as seal will be damaged.
Oil seal driving tool Driving Seals onto Shaft:(a) Coat the seal lip with grease.(b) Use seal guide like the one shown in the illustration when the shaft has steps, splines, threads or keyways.
Oil seal guideO-Rings
Use a guide when it is necessary to move O-rings over steps, splines, threads or keyways to install them. Apply a light coat of grease to O-rings before fitting them.
O-ring guideBearings
(1) When driving bearing into place, be sure to tap the race that is being fitted. (If the inner race is being fitted, tap the inner race. Likewise, if it is the outer race that is being fitted, tap the outer race.)Use fitting tools like the ones in the illustration that are appropriate for inner or outer races.
Bearing fitting tool(2) Bearings are best fitted using a press as shock loads and errors can be minimized.
Fitting bearing using a pressLock Plates
Always bend lock plates properly. The illustration on the right show some of typical lock plates being bent properly and improperly.
Typical lock plates with good and bad bendsSplit Pins and Spring Pins
As a rule, all split pins must be replaced with new ones after each removal. It is also important to bend split pins properly. Spring pins must be driven into place completely.