101401-4140 ZEXEL 9 400 613 679 BOSCH INJECTION-PUMP ASSEMBLY 9400613679 1014014140 8970331541

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 679 9400613679

ZEXEL 101401-4140 1014014140

ISUZU 8970331541 8970331541

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Buy INJECTION-PUMP ASSEMBLY 101401-4140 zexel genuine, new aftermarket engine parts with delivery

Service parts 101401-4140 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8340

3. GOVERNOR 105931-8511

4. SUPPLY PUMP 105220-5950

5. AUTOM. ADVANCE MECHANIS 105622-0731

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder 5-15300-089-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101401-4140 as INJECTION-PUMP ASSEMBLY

108622-3674 as _

Cross reference number

BOSCH 9 400 613 679 9400613679

ZEXEL 101401-4140 1014014140

ISUZU 8970331541 8970331541

Zexel num

Bosch num

Firm num

Name

101401-4140

9 400 613 679

8970331541 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1 * 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 opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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

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 11.2

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 66.7 65.1 68.3

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 290 290 290

Average injection quantity mm3/st. 8 6.7 9.3

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(11.2)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 66.7 65.7 67.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.4

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 63.3 60.1 66.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.1

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 70.7 67.5 73.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.25

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 49.6 46.4 52.8

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 49 45 53

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 95 95 103

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1250

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1350

Advance angle deg. 1.1

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 1.6

Timer adjustment_04

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
----------
T1=47
----------

Speed control lever angle

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

----------
a=30deg+-5deg b=41deg+-3deg

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(11.2)mm Rb=- Pa=89.8+-2.7kPa(674+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=66.7+-1cm3/1000st Q2=(59)+-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=13deg
----------
a=(100deg)

Information:

Fuel Filter Group
(1) Remove clips (1) and (2). Remove tube assembly (3) and elbow (4) from the fuel transfer pump on the replacement engine. Installation of new line is shown in Fuel Lines Group, Page 8.Fuel Tank Group
(1) Remove the fuel tank from the machine; see the Service Manual. (2) Fabricate boss (1) to the dimensions shown. Make 1/8" - 27 NPTF threads in one end. (3) Drill a 20.0 mm Ø (0.78" Ø) hole (A) through the bottom of the tank as shown. (4) Put boss (1) in hole (A) with the threaded end extending below the bottom of the full tank as shown. Make a 3.0 mm (0.12") fillet weld all around the boss.(5) Clean and install the fuel tank; see the Service Manual.Fuel Lines Group
(1) Remove fuel inlet hose (1) and tube assembly (2) from tube (A). (2) Install 307946 Elbow (3) and a 3J7354 Seal in the fuel transfer pump. Install 2V4869 Fitting (4) on elbow (3). Cut a 360.0 mm (14.17") length of 5P1465 Hose (5), and connect it to fitting (4) and tube assembly (A) with the former clamps.(3) Install 6D238 Valve Assembly (7) in the boss installed in the fuel tank (see Step 4, Page 7). Fasten 5G5681 Tube (8) to valve assembly (7). Use L2072 Clamp (9) to hold the other end of tube (8) in position. Install clamp (9) under bolt (10).(4) Install 307941 Elbow (11) and a 3J7354 Seal in the fuel return port of the fuel injection pump housing. Install 2V4869 Fitting (12) on elbow (11).(5) Cut a 520.0 mm (20.47") length of 5P1465 Hose (13), and connect it to fitting (12) and tube (8) with a 1P4278 Clamp (14). An optional step to the above procedure is to connect a 60.0 mm (2.36") length of 5P189 Tube to valve assembly (7). Cut a 2000.0 mm (78.75") length of 5P6442 Hose and connect it to 2V4869 Fitting (12) and to the 5P189 Tube with a 1P4278 Clamp. Tie the hose to the machine to prevent damage to the hose.Electrical System
(1) For all machines, connect the alternator wire of the harness to the alternator.(2) For machines 80U1-80U6734, remove the original voltage regulator. Put tape over the wire connection to the wiring harness so it will be out of the way. The alternator for this engine has a built in voltage regulator so the original voltage regulator is not needed for the electrical system.Flywheel Group (For Replacement of 7N9437, 1W163 or 2W7488 Engine Arrangements)
(1) Remove the flywheel from the new replacement engine.(2) Install a new 7W2290 Flywheel Assembly, and fasten it to the crankshaft with four T489 Bolts. See the Service Manual for the procedure and the bolt torque. If necessary, use of the former flywheel from the engine being replaced is acceptable.Installation Of Ether Starting Aid Group
The ether starting aid is no longer a required component of direct injection engine arrangements.(1) If the machine is equipped with an ether starting aid group, its reuse is optional. To reuse,