101401-7453 ZEXEL 9 400 612 026 BOSCH INJECTION-PUMP ASSEMBLY 9400612026 1014017453 8971784854


101401-7453 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 612 026 9400612026
ZEXEL 101401-7453 1014017453
ISUZU 8971784854 8971784854

Service parts 101401-7453 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-8760
3. GOVERNOR 105932-2623
4. SUPPLY PUMP 105230-1111
5. AUTOM. ADVANCE MECHANIS 105676-8110
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-7542
11. Nozzle and Holder 8-97200-570-2
12. Open Pre:MPa(Kqf/cm2) 18.1{185}/21.1{215}
13. NOZZLE-HOLDER 105048-3832
14. NOZZLE
15. NOZZLE SET 105019-1470

Include in #1:

101401-7453 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 026 9400612026
ZEXEL 101401-7453 1014017453
ISUZU 8971784854 8971784854


Zexel num
Bosch num
Firm num
Name
101401-7453 
101401-7454 
9 400 612 026 
8971784854  ISUZU
INJECTION-PUMP ASSEMBLY
4HG1-T * K 14BD PE4AD PE

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8310
Nozzle   105780-0120
Bosch type code   1 688 901 990
Nozzle holder   105780-2240
Opening pressure MPa   18
Opening pressure kgf/cm2   184
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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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   3.8 3.75 3.85
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
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   54 53 55
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   H
Rack position   9.1+-0.5
Pump speed r/min   315 315 315
Average injection quantity mm3/st.   23 21.7 24.3
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)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   54 53 55
Basic   *
Fixing the lever   *
Boost pressure kPa   61.3 61.3
Boost pressure mmHg   460 460
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   57.5 53.5 61.5
Fixing the lever   *
Boost pressure kPa   61.3 61.3
Boost pressure mmHg   460 460
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2-0.9
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   45.8 41.8 49.8
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   R2-0.9
Boost pressure kPa   13.3 12 14.6
Boost pressure mmHg   100 90 110
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R2(R1-0. 25)
Boost pressure kPa   48 48 48
Boost pressure mmHg   360 360 360
Timer adjustment
Pump speed r/min   1150--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1100
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1535
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-7453
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=N40 BCL=0.9+-0.1mm
----------

Speed control lever angle

Test data 101401-7453
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=42deg+-5deg b=(38.5deg)+-3deg

Stop lever angle

Test data 101401-7453
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)At pump speed bb and rack position cc, set the stopper bolt.
----------
aa=58mm bb=1500r/min cc=3.5+-0.2mm
----------
a=23deg+-5deg b=(31deg)+-5deg

0000001501 RACK SENSOR

Test data 101401-7453
Rack sensor adjustment 1. Flange type rack sensor (rack sensor adjustment -5*20) (1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures. (2)Mount the rack sensor main body to the pump main body. (3)Fix the pump lever at full. (4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist. (5)Move the pump lever two or three times. (6)Set again to full. (7)Confirm that the amplifier output voltage is Vist. (8)Fix the caution plate to the upper part of the rack sensor. (For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.) (9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=1500r/min Ra=R1(12)+1mm Vist=3.07+-0.28V
----------

0000001601 FICD

Test data 101401-7453
(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=400r/min Ra=9.1+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm

Timing setting

Test data 101401-7453
(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)At the No 1 cylinder's beginning of injection, align with the aligning mark seen through the bracket's check hole and mark the A/T's bevel C1. (5)B.T.D.C.: aa
----------
aa=7deg
----------
a=(60deg) b=(85deg)




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Group cross 101401-7453 ZEXEL

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101401-7453  

101401-7454 
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8971784854 
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