101401-0992 ZEXEL 9 400 613 594 BOSCH INJECTION-PUMP ASSEMBLY 9400613594 1014010992 8970103244

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 594 9400613594

ZEXEL 101401-0992 1014010992

ISUZU 8970103244 8970103244

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Buy INJECTION-PUMP ASSEMBLY 101401-0992 zexel genuine, new aftermarket engine parts with delivery

Service parts 101401-0992 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8800

3. GOVERNOR 105931-6741

4. SUPPLY PUMP 105210-4860

5. AUTOM. ADVANCE MECHANIS 105671-0140

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4724

11. Nozzle and Holder 8-94479-578-3

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3352

14. NOZZLE

105017-0640

15. NOZZLE SET

Include in #1:

101401-0992 as INJECTION-PUMP ASSEMBLY

106873-3342 as _

Cross reference number

BOSCH 9 400 613 594 9400613594

ZEXEL 101401-0992 1014010992

ISUZU 8970103244 8970103244

Zexel num

Bosch num

Firm num

Name

101401-0992

9 400 613 594

8970103244 ISUZU

INJECTION-PUMP ASSEMBLY
4BG1 * 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 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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.6 3.55 3.65

Rack position
Point A R=A

Beginning of injection position
Drive 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 11.3

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 69.6 68 71.2

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 350 350 350

Average injection quantity mm3/st. 9.8 8.5 11.1

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(11.3)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 69.6 68.6 70.6

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1525 1525 1525

Average injection quantity mm3/st. 82.1 78.9 85.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(11.3)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 53.1 49.9 56.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 86 78 94

Fixing the lever *

Timer adjustment

Pump speed r/min 1370--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1320

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 5 4.5 5.5

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.
----------
T1=D65
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Speed control lever angle

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

----------
a=4.5deg+-5deg b=(31.5deg)+-3deg

0000001501 FICD

Negative pressure port A (B) Screw 1. FICD adjustment (1)Set the clearance between the actuator and the speed lever at L1. (2)Fully screw in screw B. (3)Apply P1 to negative pressure port A and gradually tighten screw B. (4)Fix the screw (B) at pump speed N1 and rack position R1. (Tightening torque = T1) (5)Apply P2 to negative pressure port A and confirm that the FICD operates normally.
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L1=(3)mm P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) N1=600r/min R1=9.2+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(100deg)

Information:

(a)When regrinding journals of the crankshaft, be sure to refinish all journals to the same dimension.(b)Finish the fillet radius to R3 mm [0.1181 in.].
Crankshaft fillet finishing dimension (2)Inspection of Oil Seal Contact Surface
Check the oil seal contact surface of the crankshaft back-end, and, if the crankshaft face has been excessively worn by the oil seal, replace the oil seal and oil sleeve with replacement parts.
Inspection of oil seal contact surface(1) Installation of oil seal sleeveTo install the oil seal sleeve, coat the inner surface of the sleeve with oil, and use the crankshaft sleeve installer for driving the sleeve into place.
Be careful not to dent or scratch the outer surface of the oil seal sleeve.
Inspection of oil seal sleeveWhen the oil seal slinger becomes worn after engine operation, remove the oil seal sleeve by following the procedure below, and replace it with a replacement oil seal assembly (oil seal and oil seal sleeve).
Inspection of oil seal contact surface(2) Removal of oil seal sleeveAt three locations on the sleeve end face, hold a chisel at a right angle to the sleeve and strike with a hammer, and remove the sleeve when it becomes loose.If this method does not allow the removal of the sleeve, hold the chisel in the axial direction and lightly tap to expand and loosen the sleeve.
Be careful not to damage the crankshaft with the chisel when removing the oil seal sleeve.
Removal of oil seal sleeveMeasurement of Crankshaft Deflection
Support the crankshaft on its front and rear journals in V-blocks, and measure the runout at the center journal with a dial gage. Compare the amount of runout with the standard. If the runout is small, correct by grinding. If the runout is large, straighten with a press.If the runout exceeds the limit significantly, replace the crankshaft.
Measurement of crankshaft deflectionRemoval of Crankshaft Gear
Use the gear puller to remove the crankshaft gear. Do not remove the crankshaft gear unless the crankshaft or gear is replaced.
Removal of crankshaft gearInstallation of Crankshaft Gear
(1) Heat the gear to a temperature of 100 to 150 °C [212 to 302 °F].(2) Install the key to the crankshaft.(3) Align the gear with key and insert the gear fully.
Installation of crankshaft gearMeasurement of Cylinder Bore
(1) Using a cylinder gage, measure the cylinder bore and cylindricity. If the limit value is exceeded even at one place, bore all cylinders and replace the pistons and piston rings with oversize pistons and piston rings. Measure at three locations each in directions A and B shown in the diagram.
Measurement of inside diameter of cylinder(2) Boring of cylinders(a) Since there are two piston oversizes (0.25 mm [0.0098 in.] and 0.50 mm [0.0197 in.] oversize) as indicated above, determine the appropriate piston size to be used based on the largest cylinder bore diameter.(b) Measure the outside diameter of the piston to be used. The piston diameter measuring points are shown in the diagram.(c) Based on the measurements of the piston outside diameter, calculate the finishing dimension to be achieved by boring.A: Piston