101401-7751 ZEXEL 9 400 612 027 BOSCH INJECTION-PUMP ASSEMBLY 9400612027 1014017751 8972311811

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 027 9400612027

ZEXEL 101401-7751 1014017751

ISUZU 8972311811 8972311811

Service parts 101401-7751 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8760

3. GOVERNOR 105932-3380

4. SUPPLY PUMP 105230-1111

5. AUTOM. ADVANCE MECHANIS 105676-8130

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-7542

11. Nozzle and Holder 8-97200-570-3

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:

101401-7751 as INJECTION-PUMP ASSEMBLY

106671-8862 as _

106671-8863

Cross reference number

BOSCH 9 400 612 027 9400612027

ZEXEL 101401-7751 1014017751

ISUZU 8972311811 8972311811

Zexel num

Bosch num

Firm num

Name

101401-7751
101401-7752

9 400 612 027

8972311811 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. 3 2.5 3.5

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)Boost compensator stroke: BCL
----------
T1=N40 BCL=0.9+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=42deg+-5deg b=(38.5deg)+-3deg

Stop lever angle

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.
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aa=58mm bb=1500r/min cc=3.5+-0.2mm
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a=23deg+-5deg b=(31deg)+-5deg

0000001501 RACK SENSOR

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).
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V1=5+-0.01V N1=1500r/min Ra=R1(12)+1mm Vist=3.07+-0.28V
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0000001601 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=1000r/min L1=(1.5)mm L2=24+-0.5mm h1=0.15mm
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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

0000001701 ACS

(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.
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L1=24+-0.5mm L2=1.5+-0.5mm
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Timing setting

(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
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aa=9deg
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a=(60deg) b=(85deg)