101402-4202 ZEXEL 9 400 613 899 BOSCH INJECTION-PUMP ASSEMBLY 9400613899 1014024202 8970486852

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 899 9400613899

ZEXEL 101402-4202 1014024202

ISUZU 8970486852 8970486852

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Buy INJECTION-PUMP ASSEMBLY 101402-4202 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-4202 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8873

3. GOVERNOR 105419-0860

4. SUPPLY PUMP 105220-4932

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156637-1521

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6541

11. Nozzle and Holder 8-97013-319-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105015-4190

15. NOZZLE SET

Include in #1:

101402-4202 as INJECTION-PUMP ASSEMBLY

107691-3562 as _

Cross reference number

BOSCH 9 400 613 899 9400613899

ZEXEL 101402-4202 1014024202

ISUZU 8970486852 8970486852

Zexel num

Bosch num

Firm num

Name

101402-4202
101402-4680

9 400 613 899

8970486852 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1-T * K 14BC PE4A,5A, PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

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 3.4 3.35 3.45

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 A

Rack position 9.7

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 76.9 75.8 78

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.6+-0.5

Pump speed r/min 475 475 475

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.

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 between N = N1 and N = N2
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K=5 N1=1150r/min N2=800r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop D:Dead point
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a=(20deg)+-5deg b=(16deg)+-5deg c=(18deg)+-5deg d=13deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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----------
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.
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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)

Information:

2. Remove two short bolts (1) and two longer bolts (2) from manifold (3) and BrakeSaver housing.3. Remove the manifold from the control valve. 4. Remove the three bolts from elbows (5) and the control valve.5. Remove four bolts (4) that hold the control valve to the oil pan.6. Remove the control valve from under the oil pan.7. Make an inspection of the O-ring seals on the manifold and on the control valve. If there is wear or damage make a replacement of the O-ring seals.Install Brakesaver Control Valve
1. Put clean SAE 30 engine oil on O-ring seals (1).2. Put the control valve in position under the oil pan. Install the four bolts that hold the control valve to the oil pan.3. Install the elbow and the bolts that hold it to the side of the control valve. 4. Put SAE 30 engine oil on the O-ring seals of the manifold. Install manifold (2) in the control valve. Install the four bolts that hold the manifold to the BrakeSaver housing.5. Fill the engine with oil. See 3408 TRUCK ENGINE LUBRICATION AND MAINTENANCE GUIDE.Disassemble Brakesaver Control Valve
start by:a) remove BrakeSaver control valve 1. Remove O-ring seals (1) from the valve body.2. Remove four bolts (2) slowly and evenly from cover (4). Remove the cover.
Spring force is behind the cover at removal.
3. Remove cover (3) and the seal from the opposite end of the valve body. 4. Remove spool (8) as an assembly.5. Remove spring (7), stop (10), spring (6) and slug (9).6. Remove the seals and sleeve (5). 7. Remove bolt (11), plate (13) and diaphragm (12) from the spool. Make an inspection of the pin on the spool, and make a replacement of the pin if there is damage or wear.Assemble Brakesaver Control Valve
1. Install diaphragm (4) and plate (8) on valve spool (3). Make alignment of the hole in the plate valve with the pin on the spool. Install the bolt that holds the plate and the diaphragm in position.
When diaphragm (4) is installed on valve spool (3), make sure the fabric side is pulled down over the valve spool to make contact with it and the smooth (rubber coated) side is next to valve body.
2. Install sleeves (1) and the seals in the valve body. 3. Install the valve spool as an assembly into the valve body. As the valve spool is installed, make sure the edge of the diaphragm makes contact all the way around with the groove in the valve body. At this time the valve spool end must extend about 1.50 in. (38.1 mm) from the valve body. Push the valve spool about .25 in. (6.4 mm) - .50 in. (12.7 mm) farther into the valve body until a curved depression is caused between the valve spool and valve body. Make sure there are no wrinkles in the diaphragm. 4. Put cover (9) in position. Install the four bolts that hold the cover on the valve body. Move the valve spool in the