101401-4160 ZEXEL 9 400 612 021 BOSCH INJECTION-PUMP ASSEMBLY 9400612021 1014014160 8970418341


101401-4160 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 612 021 9400612021
ZEXEL 101401-4160 1014014160
ISUZU 8970418341 8970418341

Service parts 101401-4160 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101040-8910
3. GOVERNOR 105931-4693
4. SUPPLY PUMP 105210-6130
5. AUTOM. ADVANCE MECHANIS 105671-0191
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6241
11. Nozzle and Holder 1-15300-142-1
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105030-3201
14. NOZZLE 105015-5860
15. NOZZLE SET

Include in #1:

101401-4160 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 021 9400612021
ZEXEL 101401-4160 1014014160
ISUZU 8970418341 8970418341


Zexel num
Bosch num
Firm num
Name
101401-4160 
9 400 612 021 
8970418341  ISUZU
INJECTION-PUMP ASSEMBLY
4BD1-T * 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)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-3-4-2
Pre-stroke mm   3.4 3.35 3.45
Beginning of injection position
Drive 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   11.6
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   72.1 70.5 73.7
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   9.5+-0.5
Pump speed r/min   365 365 365
Average injection quantity mm3/st.   12.5 11.2 13.8
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(11.6)
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   72.1 71.1 73.1
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.2
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   82.6 79.4 85.8
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.1
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   53.6 49.6 57.6
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   (R1+0.1)
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   76.1 72.9 79.3
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   116 116 124
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1000+-50
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1600
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-4160
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=C52
----------

Speed control lever angle

Test data 101401-4160
F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)At M/S adjustment, confirm that M/S turns ON when speed lever is returned from full to idle and gap between speed lever and idle side stopper bolt is aa. Confirm that M/S turns OFF when speed lever is again returned from full to idle at gap bb.
----------
aa=0.1mm bb=0.25mm
----------
a=5deg+-5deg b=(25.5deg)+-3deg

Stop lever angle

Test data 101401-4160
N:Pump normal S:Stop the pump.
----------

----------
a=45deg+-5deg b=40deg+-5deg

0000001501 ACS

Test data 101401-4160
(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(11.6)mm Rb=(R1-0.15)mm Pa=79.4+-2.7kPa(596+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=72.1+-1cm3/1000st Q2=69.8+-1.6cm3/1000st

Timing setting

Test data 101401-4160
(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(100deg)




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