Information injection-pump assembly
BOSCH
9 400 612 249
9400612249
ZEXEL
101401-4272
1014014272
ISUZU
8970610272
8970610272
Rating:
Service parts 101401-4272 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 612 249
9400612249
ZEXEL
101401-4272
1014014272
ISUZU
8970610272
8970610272
Zexel num
Bosch num
Firm num
Name
101401-4272
9 400 612 249
8970610272 ISUZU
INJECTION-PUMP ASSEMBLY
4BD1 K
4BD1 K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
After adjusting injection quantity. R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
10.5
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
40.9
39.3
42.5
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
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(10.5)
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
40.9
39.9
41.9
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(10.5)
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
49.7
46.5
52.9
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.
34.5
31.3
37.7
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
Start
Timer adjustment_02
Pump speed
r/min
1050
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1580
Advance angle
deg.
5
4
5
Remarks
Finish
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=G82 N1=100r/min
----------
----------
T1=G82 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(10.5)mm
----------
a=2.5deg+-5deg b=43deg+-3deg c=(4deg)
----------
aa=R1(10.5)mm
----------
a=2.5deg+-5deg b=43deg+-3deg c=(4deg)
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=45deg+-5deg b=29deg+-5deg
----------
----------
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(10.5)mm Rb=R1-0.5mm Pa=(74.8)+-2.7kPa((561)+-20mmHg) Pb=61.6+-0.7kPa(462+-5mmHg) Q1=40.9+-1cm3/1000st Q2=(35.4)+-1.6cm3/1000st
----------
N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.5)mm Rb=R1-0.5mm Pa=(74.8)+-2.7kPa((561)+-20mmHg) Pb=61.6+-0.7kPa(462+-5mmHg) Q1=40.9+-1cm3/1000st Q2=(35.4)+-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=17deg
----------
a=(90deg)
----------
aa=17deg
----------
a=(90deg)
Information:
Start By:a. remove timing gear cover 1. Remove bolt (1) that holds the relief valve.2. Remove bolts (2) that hold suction tube to the mounting bracket. 3. Use tool (A) to remove the retaining ring that holds idler gear (3). Remove idler gear (3).4. Inspect bushing (4) in idler gear (3). If bushing replacement is necessary, use tooling (B) to remove the bushing.5. Remove bolts (4) that hold oil pump (5) to the front main bearing cap, and remove oil pump (5). Use the reverse procedures of Steps 1 through 5 for installation of the oil pump.Disassemble Oil Pump
Start By:a. remove oil pump 1. Disconnect pump suction tube assembly (2) from oil pump (3).2. Disconnect pump pressure tube (1) from oil pump (3). 3. Remove relief valve (4).
The cap under cotter pin (5) is under spring force. To prevent personal injury, be careful to hold the cap when removing cotter pin (5).
4. Remove cotter pin (5). 5. Remove cap (6), spring (7) and plunger (8) from relief valve (4). The oil pump is serviced only as an assembly. See Specifications for more information on how to check the condition of the pump.Assemble Oil Pump
1. Install plunger (3), spring (2) and cap (1) into relief valve (4). Compress spring (2) with cap (1), and install cotter pin (5). 2. Put a new gasket on relief valve (4), and install tube (6). 3. Connect tube (6) to oil pump (8).4. Put a new gasket on oil pump (8), and install oil pump suction tube (7).End By:a. install oil pump
Start By:a. remove oil pump 1. Disconnect pump suction tube assembly (2) from oil pump (3).2. Disconnect pump pressure tube (1) from oil pump (3). 3. Remove relief valve (4).
The cap under cotter pin (5) is under spring force. To prevent personal injury, be careful to hold the cap when removing cotter pin (5).
4. Remove cotter pin (5). 5. Remove cap (6), spring (7) and plunger (8) from relief valve (4). The oil pump is serviced only as an assembly. See Specifications for more information on how to check the condition of the pump.Assemble Oil Pump
1. Install plunger (3), spring (2) and cap (1) into relief valve (4). Compress spring (2) with cap (1), and install cotter pin (5). 2. Put a new gasket on relief valve (4), and install tube (6). 3. Connect tube (6) to oil pump (8).4. Put a new gasket on oil pump (8), and install oil pump suction tube (7).End By:a. install oil pump
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101401-4272
9 400 612 249
8970610272
INJECTION-PUMP ASSEMBLY
4BD1
4BD1