Information injection-pump assembly
BOSCH
9 400 613 781
9400613781
ZEXEL
101401-7671
1014017671
ISUZU
8972114450
8972114450
Rating:
Service parts 101401-7671 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97119-811-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 781
9400613781
ZEXEL
101401-7671
1014017671
ISUZU
8972114450
8972114450
Zexel num
Bosch num
Firm num
Name
101401-7671
9 400 613 781
8972114450 ISUZU
INJECTION-PUMP ASSEMBLY
4HG1 K 14BD INJECTION PUMP ASSY PE4AD PE
4HG1 K 14BD INJECTION PUMP ASSY PE4AD PE
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
4.1
4.05
4.15
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor 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
11.1
Pump speed
r/min
960
960
960
Average injection quantity
mm3/st.
38.5
36.9
40.1
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
9.8+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
20.5
19.2
21.8
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
H
Rack position
9.3+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
9.5
8.2
10.8
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
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
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=N75
----------
----------
T1=N75
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H' (rack position = aa, speed = bb)
----------
aa=(9.3)mm bb=375r/min
----------
a=40deg+-5deg b=38deg+-3deg
----------
aa=(9.3)mm bb=375r/min
----------
a=40deg+-5deg b=38deg+-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
----------
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=410r/min Ra=9.4+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=410r/min Ra=9.4+-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
----------
----------
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)
----------
aa=7deg
----------
a=(60deg) b=(85deg)
Information:
Typical Example2. Remove eight bolts (3) that fasten pipe (1) to the elbow. Remove four bolts (2) that fasten the elbow to the aftercooler cover. Remove elbow (4).
Typical Example3. Remove bracket (5) from the oil filter tube and the oil level gauge group.
Typical Example4. Remove four bolts (7) from the air inlet elbow. Remove plate (6) and elbow (8). 5. Remove two tubes (10) from the air compressor to the aftercooler.6. Remove elbows (9) from the aftercooler housing.
Typical Example
Put identification on bolts (12) because they are 6.4 mm (.25 in) longer than all other bolts. They must be installed in the same location.
7. Remove bolts (11) and (12) from cover, and remove the cover.
Put identification on bolt (14) because it is 12.7 mm (.50 in) shorter than all the other bolts. It must be installed in the same location. Remove four adapters (15). Put plugs in both holes in the aftercooler core assembly. This will keep coolant out of the engine intake manifold.
8. Remove bolts (13) and (14) that hold the core assembly in position.9. Remove the aftercooler core assembly. 10. Remove air line (17) from the fuel ratio control valve.11. Remove eight bolts (16). Remove housing assembly (18).Install Aftercooler
1. Check all seals and gaskets for damage. If damaged, use new parts for replacement.
All foreign material and dirt must be removed from the gasket surface and inside the housing and intake manifold.
2. Install housing (1) and air line (2) to the fuel control valve. 3. Install four new seals (3) on the core assembly. Put clean glycerin on the O-ring seals. 4. Install core assembly (4) inside the housing. Remove plugs in both holes of the aftercooler core assembly. Install the bolts that fasten the core to housing. Install the bolts in their original location. 5. Put clean engine oil in the bores of the adapters. Install adapters (5). 6. Put cover (6) in position on the aftercooler. Install the two bolts in position (7). These bolts are 6.4 mm (.25 in) longer than all other bolts around the housing. Install the remainder of the bolts around the housing. 7. Install elbows (8). 8. Install two tubes (9) between the air compressor and the aftercooler.
Typical Example9. Install elbow (10) and plate (11) on the aftercooler cover. Install the bracket that is a support for the oil filter tube and the oil level gauge group. Install the oil filter tube and the oil level gauge group.
Typical Example10. Install eight bolts (13) that fasten the pipe to elbow (14). Install the elbow in the turbocharger.11. Install the four bolts that fasten the elbow to aftercooler cover (12).12. Fill the engine with coolant to the correct level. See the Operation & Maintenance Manual.
Have questions with 101401-7671?
Group cross 101401-7671 ZEXEL
Isuzu
Isuzu
Nissan
Isuzu
101401-7671
9 400 613 781
8972114450
INJECTION-PUMP ASSEMBLY
4HG1
4HG1