101401-7520 ZEXEL 9 400 613 770 BOSCH INJECTION-PUMP ASSEMBLY 9400613770 1014017520 8972033730

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 770 9400613770

ZEXEL 101401-7520 1014017520

ISUZU 8972033730 8972033730

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Service parts 101401-7520 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8561

3. GOVERNOR 105932-3280

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:

101401-7520 as INJECTION-PUMP ASSEMBLY

106672-3670 as _

Cross reference number

BOSCH 9 400 613 770 9400613770

ZEXEL 101401-7520 1014017520

ISUZU 8972033730 8972033730

Zexel num

Bosch num

Firm num

Name

101401-7520

9 400 613 770

8972033730 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 B R=B

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 11.9

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 92.5 90.9 94.1

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 rack *

Injection quantity adjustment_04

Adjusting point A

Rack position R1(11.9)

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 92.5 91.5 93.5

Basic *

Fixing the lever *

Injection quantity adjustment_05

Adjusting point B

Rack position R1-0.5

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 74.5 70.5 78.5

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=K90
----------

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(11.9)-0.5mm Vist=2.44+-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:

2. Remove pipe (1) and the gasket between aftercooler cover (2) and the turbocharger. If necessary, remove the O-ring seals from the pipe.3. Remove the bolts and clamps that hold tube assemblies (3) to each end of the aftercooler. Remove tube assemblies (3) from each end of the aftercooler. If necessary, remove the O-ring seals from the tube assemblies. An O-ring seal on each end of the aftercooler core holds the adapters in position.4. Remove adapters (4) and the gaskets from each end of the aftercooler.5. Remove all bolts (5) that hold aftercooler cover (2) in position. Remove the aftercooler cover and gasket from the engine. 6. Remove aftercooler core (6) and the gasket from the engine. If necessary, remove the O-ring seals from the aftercooler core. Two of the bolts that hold the aftercooler housing in position are on the inside of the aftercooler housing.7. Remove the bolts and spacers that hold aftercooler housing (7) to the engine. Make a note of the location of the spacers. Remove the aftercooler housing and gaskets from the engine.Install Aftercooler
Inspect all O-ring seals and gaskets, and make replacements if necessary. 1. Put the gaskets and aftercooler housing (1) in position on the engine. Install the bolts and spacers that hold the aftercooler housing.2. Install the O-ring seals on the aftercooler core, and put a thin layer of clean engine oil on them. Put the gasket and aftercooler core (2) in position on the engine. 3. Put the gasket and aftercooler cover (3) in position. Install the bolts that hold the aftercooler cover. Force may be required to push the adapters around the O-ring seals on the aftercooler core. Make sure the O-ring seals stay in position on the aftercooler core.4. Put a thin layer of clean engine oil in the bores of adapters (4). Install a gasket and adapter on each end of the aftercooler core. 5. Install the O-ring seals on tube assemblies (5), and put a thin layer of clean engine oil on them. Put the tube assemblies in position on each end of the aftercooler, and install the bolts and clamps that hold them.6. Install the O-ring seals on pipe (6), and put a thin layer of clean engine oil on them. Put the pipe and gasket in position between the aftercooler and the turbocharger. Install the bolts that hold it.7. Fill the radiator with coolant to the correct level. See the Operation & Maintenance Manual.