Information injection-pump assembly
BOSCH
9 400 613 895
9400613895
ZEXEL
101402-4154
1014024154
ISUZU
8970314863
8970314863
Rating:
Service parts 101402-4154 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97013-319-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 895
9400613895
ZEXEL
101402-4154
1014024154
ISUZU
8970314863
8970314863
Zexel num
Bosch num
Firm num
Name
9 400 613 895
8970314863 ISUZU
INJECTION-PUMP ASSEMBLY
4BD1-T * K 14BC PE4A,5A, PE
4BD1-T * 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
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
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
3.4
3.35
3.45
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
9.7
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
88.5
87.4
89.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
10.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
86
84
88
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
-
Rack position
6.6+-0.5
Pump speed
r/min
440
440
440
Average injection quantity
mm3/st.
8.8
7.4
10.2
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Main spring setting
(4)Set idle sub-spring
----------
K=9
----------
----------
K=9
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
D:Dead point
----------
----------
a=(26deg)+-5deg b=(17deg)+-5deg c=(18deg)+-5deg d=13deg+-3deg
----------
----------
a=(26deg)+-5deg b=(17deg)+-5deg c=(18deg)+-5deg d=13deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=6deg+-5deg b=46deg+-5deg
----------
----------
a=6deg+-5deg b=46deg+-5deg
0000001501 LEVER
1. Variable lever adjustment
(1)Fix lever B in the idle position using the bolts C and D.
(2)Temporarily fix lever A in center of long hole.
(3)Set the dead point position temporarily and measure the lever angle.
(4)After idle adjustment, loosen the full side stopper bolt D.
(5)Move lever A in full speed direction.
(6)Fix the bolt D at the full speed position.
(7)Fix lever A using bolt E.
(8)(G) Lock using bolt.
(9)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
----------
----------
----------
----------
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:
start by:a) remove automatic timing advanceb) remove vibration damper and pulleyc) remove water pumpd) remove belt tightener idler pulleye) remove water temperature regulator (left cylinder head)1. Remove the tube assembly from the oil cooler elbow to the oil pan.2. Loosen the bolts that hold the oil pan to the cylinder block approximately 1/4" (6.4 mm). Remove the bolts that hold the oil pan to the timing gear cover.3. Fasten a hoist to the engine and lift it off tool (A). Weight of the engine is 3200 lb. (1452 kg). Make a separation of the oil pan from the cylinder block and timing gear cover. Do not damage the pan gasket.4. Put 1/4" (6.4 mm) pieces of bar stock between the pan and cylinder block at the positions the oil pan makes contact with tool (A). Lower the engine on tool (A).5. Remove the bolts from the belt tightener bracket. Remove the block and gasket. 6. Remove fumes disposal tube (1).7. Remove the bolts (4) that hold the timing gear cover to the cylinder block.8. Remove water bonnet (2).9. Remove timing gear cover (3).
Do not cause damage to the crankshaft front seal when the cover is removed.
10. Check the condition of the O-ring seal on the fuel injection pump housing.Install Timing Gear Cover
1. Put clean engine oil on the O-ring seal for the fuel injection pump housing, the crankshaft front seal and wear sleeve.2. Install tool (B) in the crankshaft front seal.3. Install a new gasket on the timing gear cover. Put timing gear cover (1) in position on the dowels in the cylinder block. Make sure it is against the cylinder block all around.4. Install the bolts that hold the cover in position. Remove tool (B) from the crankshaft front seal.5. Install the water bonnet, the fumes disposal tube and the block for the belt tightener bracket.6. Fasten a hoist to the engine and lift it off tool (A). Remove the bar stock from between the cylinder block and oil pan. Tighten the bolts that hold the oil pan to the cylinder block.7. Install the bolts that hold the oil pan to the timing gear cover. Put the engine back on tool (A).8. Install the tube assembly between the oil pan and oil cooler.end by:a) install water temperature regulator (left cylinder head)b) install belt tightener idler pulleyc) install water pumpd) install vibration damper and pulleye) install automatic timing advance
Do not cause damage to the crankshaft front seal when the cover is removed.
10. Check the condition of the O-ring seal on the fuel injection pump housing.Install Timing Gear Cover
1. Put clean engine oil on the O-ring seal for the fuel injection pump housing, the crankshaft front seal and wear sleeve.2. Install tool (B) in the crankshaft front seal.3. Install a new gasket on the timing gear cover. Put timing gear cover (1) in position on the dowels in the cylinder block. Make sure it is against the cylinder block all around.4. Install the bolts that hold the cover in position. Remove tool (B) from the crankshaft front seal.5. Install the water bonnet, the fumes disposal tube and the block for the belt tightener bracket.6. Fasten a hoist to the engine and lift it off tool (A). Remove the bar stock from between the cylinder block and oil pan. Tighten the bolts that hold the oil pan to the cylinder block.7. Install the bolts that hold the oil pan to the timing gear cover. Put the engine back on tool (A).8. Install the tube assembly between the oil pan and oil cooler.end by:a) install water temperature regulator (left cylinder head)b) install belt tightener idler pulleyc) install water pumpd) install vibration damper and pulleye) install automatic timing advance