101401-4254 ZEXEL 9 400 613 687 BOSCH INJECTION-PUMP ASSEMBLY 9400613687 1014014254 8970479571

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 687 9400613687

ZEXEL 101401-4254 1014014254

ISUZU 8970479571 8970479571

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Buy INJECTION-PUMP ASSEMBLY 101401-4254 zexel genuine, new aftermarket engine parts with delivery

Service parts 101401-4254 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8980

3. GOVERNOR 105931-9232

4. SUPPLY PUMP 105210-6150

5. AUTOM. ADVANCE MECHANIS 105676-5010

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105048-3670

14. NOZZLE

105017-1210

15. NOZZLE SET

Include in #1:

101401-4254 as INJECTION-PUMP ASSEMBLY

101672-2480 as _

Cross reference number

BOSCH 9 400 613 687 9400613687

ZEXEL 101401-4254 1014014254

ISUZU 8970479571 8970479571

Zexel num

Bosch num

Firm num

Name

101401-4254

9 400 613 687

8970479571 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 134424-3920

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 12

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 60.9 59.3 62.5

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 285 285 285

Average injection quantity mm3/st. 10 8.7 11.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12)

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 60.9 59.9 61.9

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 83.7 79.7 87.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 79 79 111

Fixing the lever *

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 5 4.5 5.5

Remarks
Measure the actual speed, stop

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.
----------
T1=G97
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=43deg+-5deg b=37deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
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=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)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=11deg
----------
a=(60deg) b=(85deg)

Information:

Start By:a. remove radiator 1. Remove the four bolts and remove fan blade (1) and extension. 2. Loosen bolts (2) and remove fan belt (4). Loosen clamps (3) and disconnect the two hoses. Remove nut (5) from water pump fan pulley (6). 3. Install tooling (A) and remove fan pulley (6). 4. Remove four bolts (7) and remove the water pump and gasket. At the time of assembly, tighten nut (5) to the torque of 80 N m (60 lb.ft.) Install in the reverse order.Disassemble Water Pump
Start By:a. remove water pump 1. Remove key (1) from the shaft. 2. Remove pump housing (2) from the rear housing. 3. Remove snap ring (3) with tool (A). 4. Put the water pump housing in position on a press. Install tool (B) and remove the shaft assembly from the impeller and water pump housing. 5. Remove seals (4) from the water pump housing if they are damaged. 6. Put shaft assembly (5) in position in a press. Install tool (B) and remove bearings (6) and spacer (7) from the shaft.Assemble Water Pump
1. Put one of the shaft's bearings in position in a press. Make sure there is support for the inner race of the bearing. Push shaft (1) on to bearing (2). 2. Install spacer (4) on the shaft. Put second bearing (3) in position and push the shaft on to it. 3. Install seal (6) and flange (5) in the water pump housing. 4. Put 2S3230 Bearing Lubricant on the bearings. Put the water pump housing in position on a press and install shaft assembly (7) in the housing. 5. Install snap ring (8) over the bearings with tool (A). 6. Install the water seal in the housing with tooling (B). 7. Install seal (9) on the shaft assembly. 8. Install impeller (10) on the shaft with tooling (C) and a press. The clearance between the impeller blade and pump body must be 0.30 to 0.81 mm (.012 to .032 in). 9. Install a new gasket on water pump housing (12). Install housing (12) on the rear housing with nuts (11) that hold it. 10. Install key (13) in the shaft.End By:a. install water pump