Information injection-pump assembly
BOSCH
9 400 613 685
9400613685
ZEXEL
101401-4222
1014014222
ISUZU
8970468732
8970468732
Rating:
Service parts 101401-4222 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97114-015-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 685
9400613685
ZEXEL
101401-4222
1014014222
ISUZU
8970468732
8970468732
Zexel num
Bosch num
Firm num
Name
9 400 613 685
8970468732 ISUZU
INJECTION-PUMP ASSEMBLY
4HF1 * K 14BC INJECTION PUMP ASSY PE4A,5A, PE
4HF1 * K 14BC INJECTION PUMP ASSY PE4A,5A, PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
4.1
4.05
4.15
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.7
Pump speed
r/min
960
960
960
Average injection quantity
mm3/st.
70.4
68.8
72
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
325
325
325
Average injection quantity
mm3/st.
8.7
7.4
10
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(11.7)
Pump speed
r/min
960
960
960
Average injection quantity
mm3/st.
70.4
69.4
71.4
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.45
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
90.1
86.1
94.1
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
79
79
111
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1375--
Advance angle
deg.
0
0
0
Remarks
Start
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
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=G61
----------
----------
T1=G61
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=41deg+-5deg b=40deg+-3deg
----------
----------
a=41deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
0000001501 FICD
(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=450r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=450r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm
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)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=11deg
----------
a=(60deg) b=(85deg)
----------
aa=11deg
----------
a=(60deg) b=(85deg)
Information:
Introduction
The 7C8966, 7C8972, 8N5651, 8N5887, 9N0495, and 9N5864 Fuel Injection Pump Groups (new), or the 0R0766, 0R0902, 0R0903, 0R2374, and 0R2385 Fuel Injection Pump Group [remanufactured - (reconditioning has been done to a used fuel injection pump and governor group to give the same quality as a new pump group)] are service replacements for the fuel injection pump and governor groups used on 3208 engines, according to the adaptability shown in the chart. These service groups have only those gaskets and seals that are needed to install the fuel injection pump and governor on the engine.Reference: Parts Manual, Service Manual, Engine Information Plate, Fuel Setting Information Microfiche, Fuel System and Related Information MicroficheDo not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.Service Group Chart
Removal and Installation
1. Remove the pump and governor from the engine. Refer to the Service Manual.
When a replacement fuel injection pump and governor is installed on an engine (or when replacement parts are put in a fuel injection pump and governor), use the information on the engine information plate and always check engine low idle speed, set point and the fuel setting dimension. These settings and dimensions must be checked and adjustments made by a mechanic that has the necessary training in fuel system maintenance. Before the fuel system checks and adjustment are made, remove the original factory fuel system seal. After all fuel system work has been completed, install your Dealer seal as a replacement seal. Refer to Fuel System and Related Information or Fuel Setting Information for additional specifications.
2. Put the new service pump group in a 2P8315 Bracket Assembly (1) so it will be easier to work on. Remove the shut-off solenoid and the solenoid ground wire from the old fuel system. Remove the fuel line fittings from the old fuel system. Install these parts in the same location on the new fuel system.3. Locate the engine serial number and write it down. Make reference to the Fuel Setting Information or Fuel System and Related Information to find the part number of the governor high idle spring that is needed for the engine. The same part number governor high idle spring given in the Fuel Setting Information, or the Fuel System and Related Information must be installed in the new service pump group. The 9L6508 High Idle Spring is already installed in the service pump and governor groups. The governor high idle spring needs to be changed only if the needed part number is different than 9L6508. If it is necessary to change the high idle spring, refer to the Service Manual. The part number of the low idle spring is 4N5663 and is the same for all fuel systems.4. A 4N0527 Overfueling Spring is installed in the service pump and governor groups. Refer to the Parts Manual to determine which overfueling spring is required. If the overfueling spring must be changed, refer to the Service Manual for the
The 7C8966, 7C8972, 8N5651, 8N5887, 9N0495, and 9N5864 Fuel Injection Pump Groups (new), or the 0R0766, 0R0902, 0R0903, 0R2374, and 0R2385 Fuel Injection Pump Group [remanufactured - (reconditioning has been done to a used fuel injection pump and governor group to give the same quality as a new pump group)] are service replacements for the fuel injection pump and governor groups used on 3208 engines, according to the adaptability shown in the chart. These service groups have only those gaskets and seals that are needed to install the fuel injection pump and governor on the engine.Reference: Parts Manual, Service Manual, Engine Information Plate, Fuel Setting Information Microfiche, Fuel System and Related Information MicroficheDo not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.Service Group Chart
Removal and Installation
1. Remove the pump and governor from the engine. Refer to the Service Manual.
When a replacement fuel injection pump and governor is installed on an engine (or when replacement parts are put in a fuel injection pump and governor), use the information on the engine information plate and always check engine low idle speed, set point and the fuel setting dimension. These settings and dimensions must be checked and adjustments made by a mechanic that has the necessary training in fuel system maintenance. Before the fuel system checks and adjustment are made, remove the original factory fuel system seal. After all fuel system work has been completed, install your Dealer seal as a replacement seal. Refer to Fuel System and Related Information or Fuel Setting Information for additional specifications.
2. Put the new service pump group in a 2P8315 Bracket Assembly (1) so it will be easier to work on. Remove the shut-off solenoid and the solenoid ground wire from the old fuel system. Remove the fuel line fittings from the old fuel system. Install these parts in the same location on the new fuel system.3. Locate the engine serial number and write it down. Make reference to the Fuel Setting Information or Fuel System and Related Information to find the part number of the governor high idle spring that is needed for the engine. The same part number governor high idle spring given in the Fuel Setting Information, or the Fuel System and Related Information must be installed in the new service pump group. The 9L6508 High Idle Spring is already installed in the service pump and governor groups. The governor high idle spring needs to be changed only if the needed part number is different than 9L6508. If it is necessary to change the high idle spring, refer to the Service Manual. The part number of the low idle spring is 4N5663 and is the same for all fuel systems.4. A 4N0527 Overfueling Spring is installed in the service pump and governor groups. Refer to the Parts Manual to determine which overfueling spring is required. If the overfueling spring must be changed, refer to the Service Manual for the