Information injection-pump assembly
BOSCH
9 400 610 453
9400610453
ZEXEL
101402-4090
1014024090
ISUZU
8970208800
8970208800
Rating:
Service parts 101402-4090 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94130-074-3
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 453
9400610453
ZEXEL
101402-4090
1014024090
ISUZU
8970208800
8970208800
Zexel num
Bosch num
Firm num
Name
9 400 610 453
8970208800 ISUZU
INJECTION-PUMP ASSEMBLY
4BD1-PY * K 14BC PE4A,5A, PE
4BD1-PY * K 14BC 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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive 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
A
Rack position
9.5
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
53.4
51.9
54.9
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.9+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
9.6
8.2
11
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Set idle sub-spring
(3)Main spring setting
(4)Rack difference from N = N1
(5)Rack difference between N = N2 and N = N3
----------
K=11 N1=1200r/min N2=1200r/min N3=600r/min
----------
----------
K=11 N1=1200r/min N2=1200r/min N3=600r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=13deg+-5deg b=24deg+-5deg
----------
----------
a=13deg+-5deg b=24deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=19deg+-5deg b=53deg+-5deg
----------
----------
a=19deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=18deg
----------
a=(90deg)
----------
aa=18deg
----------
a=(90deg)
Information:
1. Remove the bolts and exhaust support (1) and the extension as a unit. 2. Remove extension (3) from the support.3. Remove two seal rings (2) from the extension. 4. Remove two bolts (5) from the clips.5. Remove the bolts and disconnect oil line (4) from the turbocharger. Remove the gasket. 6. Remove bolts (6) and disconnect the drain line from the turbocharger.7. Remove the gasket. 8. Remove bolts (7) that hold the manifold to the aftercooler. 9. Install tool (A) on the turbocharger and fasten a hoist.10. Remove bolts (9) that hold the turbocharger to the support bracket. Remove turbocharger (8) and the gasket. The weight of the turbocharger is 55 lb. (25 kg).11. Remove pipe (10) and the manifold from the turbocharger as a unit.Install Turbocharger
1. Install pipe (3) and the manifold as a unit on the turbocharger.2. Install tool (A) and fasten a hoist.3. Put turbocharger (1) in position and install gasket (2).4. Put 5P3931 Anti-Seize Compound on the bolts that hold the turbocharger in position. Install the bolts and tigthen them to a torque of 40 4 lb.ft. (54 5 N m). 5. Put gasket (4) in position and install the bolts. 6. Put gasket (5) and tube (6) in position and install the bolts. Put 5P3931 Anti-Seize Compound on the bolts. 7. Put gasket (7) and tube (8) in position. Put 5P3931 Anti-Seize Compound on the bolts and install them. 8. Put clips (9) and the bolts in position. 9. Put seal rings (10) in position on extension (11). Install the extension in the support. 10. Put support (12) and the extension in position. Put 5P3931 Anti-Seize Compound on the bolts. Install the bolts and tighten them to a torque of 40 4 lb.ft. (54 5 N m).
1. Install pipe (3) and the manifold as a unit on the turbocharger.2. Install tool (A) and fasten a hoist.3. Put turbocharger (1) in position and install gasket (2).4. Put 5P3931 Anti-Seize Compound on the bolts that hold the turbocharger in position. Install the bolts and tigthen them to a torque of 40 4 lb.ft. (54 5 N m). 5. Put gasket (4) in position and install the bolts. 6. Put gasket (5) and tube (6) in position and install the bolts. Put 5P3931 Anti-Seize Compound on the bolts. 7. Put gasket (7) and tube (8) in position. Put 5P3931 Anti-Seize Compound on the bolts and install them. 8. Put clips (9) and the bolts in position. 9. Put seal rings (10) in position on extension (11). Install the extension in the support. 10. Put support (12) and the extension in position. Put 5P3931 Anti-Seize Compound on the bolts. Install the bolts and tighten them to a torque of 40 4 lb.ft. (54 5 N m).