101401-4571 ZEXEL 9 400 613 491 BOSCH INJECTION-PUMP ASSEMBLY


Information injection-pump assembly

BOSCH 9 400 613 491 9400613491
ZEXEL 101401-4571 1014014571
ISUZU 8971140060 8971140060

Service parts 101401-4571 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-8110
3. GOVERNOR 105931-9493
4. SUPPLY PUMP 105210-6100
5. AUTOM. ADVANCE MECHANIS 105676-5030
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5792
11. Nozzle and Holder 8-97114-017-0
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105048-3673
14. NOZZLE 105017-1590
15. NOZZLE SET

Include in #1:

101401-4571 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 491 9400613491
ZEXEL 101401-4571 1014014571
ISUZU 8971140060 8971140060


Zexel num Bosch num Firm num Firm Name
101401-4571 
101401-4900 
9 400 613 491  8971140060  ISUZU INJECTION-PUMP ASSEMBLY
4HF1 K 14BC INJECTION PUMP ASSY PE4A,5A, PE

Calibration Data:



Adjustment conditions
Test oil   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   L
Left


Injection timing adjustment
Direction of rotation (viewed from drive side)   L
Left
Injection order   1-3-4-2
Pre-stroke mm   4.1 4.05 4.15
Rack position   R=A
Point A
Beginning of injection position   NO.1
Governor side
Difference between angles 1 deg.   90 89.5 90.5
Cal 1-3
Difference between angles 2 deg.   180 179.5 180.5
Cal 1-4
Difference between angles 3 deg.   270 269.5 270.5
Cyl.1-2


Injection quantity adjustment
Adjusting point   -
Rack position   12.6
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   75.4 73.8 77
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   285 285 285
Average injection quantity mm3/st.   15.5 14.2 16.8
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   A
Rack position   R1(12.6)
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   75.4 74.4 76.4
Basic   *
Fixing the lever   *


Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.2
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   86.3 82.3 90.3
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   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 101401-4571 N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=H96
----------



Speed control lever angle

Test data 101401-4571 F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=41deg+-5deg b=35deg+-3deg



Stop lever angle

Test data 101401-4571 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 101401-4571 (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=440r/min Ra=9.2+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm



Timing setting

Test data 101401-4571 (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=10deg
----------
a=(60deg) b=(85deg)





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Group cross 101401-4571 ZEXEL

Isuzu 

101401-4500  9 400 613 706  8970903721  INJECTION-PUMP ASSEMBLY
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