101401-7740 ZEXEL 9 400 613 089 BOSCH INJECTION-PUMP ASSEMBLY 9400613089 1014017740 8972256630


101401-7740 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 089 9400613089
ZEXEL 101401-7740 1014017740
ISUZU 8972256630 8972256630

Service parts 101401-7740 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-8760
3. GOVERNOR 105932-3380
4. SUPPLY PUMP 105230-1111
5. AUTOM. ADVANCE MECHANIS 105676-8120
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:

101401-7740 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 089 9400613089
ZEXEL 101401-7740 1014017740
ISUZU 8972256630 8972256630


Zexel num
Bosch num
Firm num
Name
101401-7740 
9 400 613 089 
8972256630  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 -4 4
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   H
Rack position   9.1+-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 101401-7740
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 101401-7740
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

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

Stop lever angle

Test data 101401-7740
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 ACS

Test data 101401-7740
(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=1000r/min L1=(1.5)mm L2=24+-0.5mm h1=0.15mm
----------
Ra=R1(12)mm Rb=(R1-0.2)mm Pa=(79.4)+-2.7kPa((596)+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=54+-1cm3/1000st Q2=53+-2cm3/1000st

0000001601 ACS

Test data 101401-7740
(A) Aneroid compensator (B) Set screw (C) Boost pressure inlet (D) Rack positioning screw (E): Aneroid compensator main body (F) Boost compensator spring (G): Aneroid compensator spring (H): Adjusting notch (I) Push rod 1. Instructions for adjusting the boost compensator with the aneroid compensator (1)Select a pushrod to obtain L1 at full boost. (2)Remove the aneroid compensator main body. (3)Adjust the booster compensator stroke by turning the screw at (D. (4)Adjust the beginning of boost compensator operation by turning the notch at (H). (5)Install the aneroid compensator at full boost state. (6)Turn (B)'s set screw so that the distance between the snapring and the body is L2. (7)Screw in the aneroid compensator main body and adjust the point where it comes into play.
----------
L1=24+-0.5mm L2=1.5+-0.5mm
----------

0000001701 RACK SENSOR

Test data 101401-7740
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
----------

Timing setting

Test data 101401-7740
(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=9deg
----------
a=(60deg) b=(85deg)




Have questions with 101401-7740?





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