101401-7600 ZEXEL 9 400 613 776 BOSCH INJECTION-PUMP ASSEMBLY 9400613776 1014017600 8972033810

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 776 9400613776

ZEXEL 101401-7600 1014017600

ISUZU 8972033810 8972033810

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Service parts 101401-7600 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8410

3. GOVERNOR 105932-3160

4. SUPPLY PUMP 105210-6370

5. AUTOM. ADVANCE MECHANIS 105676-5150

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6051

11. Nozzle and Holder 8-97119-812-0

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

13. NOZZLE-HOLDER 105048-3673

14. NOZZLE

105017-1860

15. NOZZLE SET

Include in #1:

101401-7600 as INJECTION-PUMP ASSEMBLY

106671-8681 as _

Cross reference number

BOSCH 9 400 613 776 9400613776

ZEXEL 101401-7600 1014017600

ISUZU 8972033810 8972033810

Zexel num

Bosch num

Firm num

Name

101401-7600

9 400 613 776

8972033810 ISUZU

INJECTION-PUMP ASSEMBLY
4HF1 K 14BC INJECTION PUMP ASSY PE4A,5A, 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 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)
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. 57 55.4 58.6

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 9.8+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 15.5 14.2 16.8

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. 57 56 58

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 68.5 64.5 72.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 45.1 41.1 49.1

Fixing the lever *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 5 4.5 5.5

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=L48
----------

Speed control lever angle

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

----------
a=41deg+-5deg b=35.5deg+-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=440r/min Ra=9.2+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)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=8deg
----------
a=(60deg) b=(85deg)

Information:

2. Remove covers (1) and (2) from the back side of the timing gear plate. 3. Remove the two bolts and clamp from location (X) that hold the crankshaft front seal adapter in position. Remove the crankshaft front seal adapter and front seal from the engine as a unit.4. Remove all bolts (3) that hold the timing gear cover in position on the engine. Remove timing gear cover (4) and the gasket from the engine.Install Timing Gear Cover
1. Put the gasket and timing gear cover (1) in position on the engine, and install the bolts that hold it. Tighten the two bolts at location (X) to a torque of 23 4 N m (17 3 lb ft).2. Put the crankshaft front seal adapter and seal in position in the timing gear cover. Install the clamp that holds it. 3. Put the gasket, cover (2) and clamp (3) in position. Install the bolts that hold them. Install the O-ring seal, cover (4) and the bolts that hold them.4. Trim the timing gear cover gasket so it is even with the bottom of the cylinder block.5. Put a thin coat of 3S6252 RTV Silicone Adhesive/Sealant to the bottom surface of the timing gear cover gasket. Remove the shims, and install the oil pan bolts. If it was necessary to remove the oil pan plate, see topic, "Remove & Install Oil Pan Plate". Install the oil pan plate.End By:a. install vibration damper and pulley (3306)b. install crankshaft pulley (3304)c. install gauge group (if equipped)d. install front supporte. install water pump