101402-4211 ZEXEL 9 400 613 900 BOSCH INJECTION-PUMP ASSEMBLY 9400613900 1014024211 8970486831

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 900 9400613900

ZEXEL 101402-4211 1014024211

ISUZU 8970486831 8970486831

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Service parts 101402-4211 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8990

3. GOVERNOR 105419-0561

4. SUPPLY PUMP 105220-7300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156637-2721

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6521

11. Nozzle and Holder 8-97030-285-1

12. Open Pre:MPa(Kqf/cm2) 14.7(150)

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105015-3930

15. NOZZLE SET

Include in #1:

101402-4211 as INJECTION-PUMP ASSEMBLY

107691-3601 as _

Cross reference number

BOSCH 9 400 613 900 9400613900

ZEXEL 101402-4211 1014024211

ISUZU 8970486831 8970486831

Zexel num

Bosch num

Firm num

Name

101402-4211

9 400 613 900

8970486831 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1 * 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 3.6 3.55 3.65

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 9.8

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 58.6 57.5 59.7

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.7+-0.5

Pump speed r/min 440 440 440

Average injection quantity mm3/st. 10 8.6 11.4

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
----------
K=5
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Speed control lever angle

F:Full speed I:Idle D:Dead point S:Stop
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a=(18deg)+-5deg b=(14deg)+-5deg c=(18deg)+-5deg d=13deg+-3deg

Stop lever angle

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

----------
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=16deg
----------
a=(90deg)

Information:

start by:a) remove oil pump1. Remove bolt and washer that hold gear on the shaft. 2. Use tooling (A) to remove drive gear (1) from shaft. Remove the key from shaft. 3. Remove retainer (3) for bypass valve.4. Remove spring and bypass valve.5. Remove the cover (2) from pump body. 6. Use tooling (B) to remove bearings from the cover. 7. Remove gears (5) from pump body (4).8. Use tooling (B) to remove bearings from pump body.Assemble Oil Pump
1. Use tooling (A) to install the bearings in the main pump body until they are even with the outside surface of the pump body. Install the bearings so the junctions in the bearings are 30° 15° from the center of the bearing bores and toward the oil pump outlet passage (2) as shown. 2. Install idler gear (1) and drive gear (3) in the oil pump body. Put clean oil on the bearings and gears. 3. Use tooling (A) to install the bearings in cover (4) until they are even with the outside surface of the cover. Install the bearings so the junctions in the bearings are 30° 15° from the center of the bearing bores and toward the oil pump outlet passage as shown. 4. Install bypass valve (5), spring (6), spacer and the retainer in the pump body.5. Install the key on the shaft. 6. Install gear (7) on the shaft. Install the washer and bolt that holds the gear on the shaft.7. Make sure the pump turns freely by hand after it is assembled.end by:a) install oil pump