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

Information Cross number Calibration Data Calibration Data Ex

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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

108622-3706 as _

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

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

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

N:Pump normal S:Stop the pump.
----------

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

0000001501 ACS

(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

(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)