101401-7510 ZEXEL 9 400 613 769 BOSCH INJECTION-PUMP ASSEMBLY 9400613769 1014017510 8972033720

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 769 9400613769

ZEXEL 101401-7510 1014017510

ISUZU 8972033720 8972033720

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Service parts 101401-7510 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8561

3. GOVERNOR 105932-3270

4. SUPPLY PUMP

105210-6380

5. AUTOM. ADVANCE MECHANIS 105676-8090

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6041

11. Nozzle and Holder 8-97119-811-0

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

13. NOZZLE-HOLDER 105048-3673

14. NOZZLE

105017-1850

15. NOZZLE SET

Include in #1:

101401-7510 as INJECTION-PUMP ASSEMBLY

106671-8670 as _

Cross reference number

BOSCH 9 400 613 769 9400613769

ZEXEL 101401-7510 1014017510

ISUZU 8972033720 8972033720

Zexel num

Bosch num

Firm num

Name

101401-7510

9 400 613 769

8972033720 ISUZU

INJECTION-PUMP ASSEMBLY
4HG1 K 14BD INJECTION PUMP ASSY PE4AD 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 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 11.1

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 68.5 66.9 70.1

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 9.4+-0.5

Pump speed r/min 310 310 310

Average injection quantity mm3/st. 11 9.7 12.3

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 H

Rack position 9.4+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10.5 9.2 11.8

Fixing the lever *

Injection quantity adjustment_04

Adjusting point A

Rack position R1(11.1)

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 68.5 67.5 69.5

Basic *

Fixing the lever *

Injection quantity adjustment_05

Adjusting point B

Rack position R1+0.55

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 89.5 85.5 93.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point C

Rack position R1-0.2

Pump speed r/min 520 520 520

Average injection quantity mm3/st. 47.6 43.6 51.6

Fixing the lever *

Injection quantity adjustment_07

Adjusting point D

Rack position R1+0.15

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 76 72 80

Fixing the lever *

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 6 5.5 6.5

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.
----------
T1=N20
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (rack position = aa, speed = bb)
----------
aa=(9.4)mm bb=325r/min
----------
a=41.5deg+-5deg b=40.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)At pump speed bb and rack position cc, set the stopper bolt.
----------
aa=58mm bb=1600r/min cc=5+-0.2mm
----------
a=23deg+-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=410r/min Ra=9.2+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm

0000001601 RACK SENSOR

Rack sensor adjustment 1. Flange type rack sensor (rack sensor adjustment -5*20) (1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures. (2)Mount the rack sensor main body to the pump main body. (3)Fix the pump lever at full. (4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist. (5)Move the pump lever two or three times. (6)Set again to full. (7)Confirm that the amplifier output voltage is Vist. (8)Fix the caution plate to the upper part of the rack sensor. (For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.) (9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=960r/min Ra=R1(11.1)mm Vist=2.33+-0.28V
----------

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Timing device stamping (4)At the No 1 cylinder's beginning of injection, align with the aligning mark seen through the bracket's check hole and mark the A/T's bevel C1. (5)B.T.D.C.: aa
----------
aa=7deg
----------
a=(60deg) b=(85deg)

Information:

Start By:a. remove turbocharger 1. Install the turbocharger on Tool (A).2. Put alignment marks on the two housings and cartridge assembly of the turbocharger for correct alignment during assembly.3. Loosen clamp (3), and remove compressor housing (4) from cartridge assembly (2).4. Loosen the remaining clamp, and remove cartridge assembly (2) from turbine housing (1).
Typical Example5. Put the cartridge group (shown in the illustration) with nut (16) up in Tool (B). Use a 5S9566 Sliding T-Wrench and a universal socket to remove nut (16) that holds the compressor wheel (15) to the wheel assembly (19).6. Remove compressor wheel (15) and housing assembly (6) from wheel assembly (19). Remove piston ring (13) from the wheel assembly.7. Use Tool (C), and remove snap ring (5) from housing assembly (6). Remove insert (14) and sleeve (18) from the housing assembly. Remove seal (22) from insert (14). Remove ring (20) from sleeve (18).8. Remove oil deflector (23), thrust ring (21), bearing assembly (7), spacer sleeve (24) and thrust ring (8) from housing assembly (6).9. Use Tool (D), and remove snap ring (9) from the housing assembly. Remove bearing (25). Remove snap ring (10) with Tool (D).10. Use Tool (D), and remove snap ring (12) from the housing assembly. Remove bearing (26). Remove snap ring (11) with Tool (D).11. Check all the parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 for turbocharger reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018. The following steps are for assembly of the turbocharger.12. Make sure that all the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, put clean engine oil into the oil inlet of the turbocharger.
Make sure the snap rings that hold bearings (25) and (26) in housing assembly (6) are installed with the round edge of the outside diameter toward the bearing.
13. Install snap ring (11) with Tool (D). Install bearing (26). Install snap ring (12) with Tool (D).14. Install snap ring (10) with Tool (D). Install bearing (25). Install snap ring (9) with Tool (D).15. Put wheel assembly (19) in position on Tool (B) with the threaded portion end up. Put 6V2055 High Vacuum Grease in the groove for piston ring (13) at assembly to one half or more of the depth of the groove all the way around.16. Install piston ring (13) in the groove in wheel assembly (19).17. Put housing assembly (6) in position on wheel assembly (19).18. Install thrust ring (8) and spacer sleeve (24) on wheel assembly (19).19. Make sure the screen is in place in bearing assembly (7). Install bearing assembly (7) over spacer sleeve (24). Make sure the screen in the bearing assembly is facing toward housing assembly (6) when it is installed.20. Install thrust ring (21) and oil deflector (23)