101401-4192 ZEXEL 9 400 613 682 BOSCH INJECTION-PUMP ASSEMBLY 9400613682 1014014192 8970459552


101401-4192 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 682 9400613682
ZEXEL 101401-4192 1014014192
ISUZU 8970459552 8970459552

Include in #1:

Cross reference number

BOSCH 9 400 613 682 9400613682
ZEXEL 101401-4192 1014014192
ISUZU 8970459552 8970459552


Zexel num
Bosch num
Firm num
Name
101401-4192 
101401-4330 
9 400 613 682 
8970459552  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   105780-8140
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   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
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   11.7
Pump speed r/min   960 960 960
Average injection quantity mm3/st.   70.4 68.8 72
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   285 285 285
Average injection quantity mm3/st.   8.5 7.2 9.8
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(11.7)
Pump speed r/min   960 960 960
Average injection quantity mm3/st.   70.4 69.4 71.4
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.45
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   90.1 86.1 94.1
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   79 79 111
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   1500
Advance angle deg.   3.3 2.8 3.8
Timer adjustment_04
Pump speed r/min   1600--
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-4192
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=G61
----------

Speed control lever angle

Test data 101401-4192
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=43deg+-5deg b=42deg+-3deg

Stop lever angle

Test data 101401-4192
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 101401-4192
(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=515r/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=9.2+-0.1mm
----------

Timing setting

Test data 101401-4192
(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=11deg
----------
a=(60deg) b=(85deg)




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Group cross 101401-4192 ZEXEL

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