101401-4040 ZEXEL 9 400 613 673 BOSCH INJECTION-PUMP ASSEMBLY 9400613673 1014014040 8970186633


101401-4040 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 673 9400613673
ZEXEL 101401-4040 1014014040
ISUZU 8970186633 8970186633

Service parts 101401-4040 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101040-8840
3. GOVERNOR 105931-7251
4. SUPPLY PUMP 105210-6480
5. AUTOM. ADVANCE MECHANIS 105676-5001
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5110
11. Nozzle and Holder 8-94388-787-0
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105048-3550
14. NOZZLE 105017-1130
15. NOZZLE SET

Include in #1:

101401-4040 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 673 9400613673
ZEXEL 101401-4040 1014014040
ISUZU 8970186633 8970186633


Zexel num
Bosch num
Firm num
Name
101401-4040 
101401-4090 
9 400 613 673 
8970186633  ISUZU
INJECTION-PUMP ASSEMBLY
4HF1 * K

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8210
Nozzle   105780-0070
Bosch type code   DN12SD12T-1
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   3.9 3.85 3.95
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   12.8
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   72.8 71.2 74.4
Max. variation between cylinders %   0 -2.5 2.5
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   350 350 350
Average injection quantity mm3/st.   8.4 7.1 9.7
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(12.8)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   72.8 71.8 73.8
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.5
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   88.5 84.5 92.5
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   80 80 112
Fixing the lever   *
Timer adjustment
Pump speed r/min   1375--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1325
Advance angle deg.   0.3
Timer adjustment_03
Pump speed r/min   1575
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-4040
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=E87
----------

Speed control lever angle

Test data 101401-4040
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=40deg+-5deg b=(34deg)+-3deg

Stop lever angle

Test data 101401-4040
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg

0000001501 FICD

Test data 101401-4040
(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=500r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm

0000001601 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=1100r/min Ra=9+-0.1mm
----------

Timing setting

Test data 101401-4040
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(60deg)




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