101402-4440 ZEXEL 9 400 610 462 BOSCH INJECTION-PUMP ASSEMBLY 9400610462 1014024440 8971332270

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 462 9400610462

ZEXEL 101402-4440 1014024440

ISUZU 8971332270 8971332270

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Buy INJECTION-PUMP ASSEMBLY 101402-4440 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-4440 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8311

3. GOVERNOR 105419-1960

4. SUPPLY PUMP 105220-6260

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-8621

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:

101402-2102 as _

101402-4440 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 462 9400610462

ZEXEL 101402-4440 1014024440

ISUZU 8971332270 8971332270

Zexel num

Bosch num

Firm num

Name

101402-4440

9 400 610 462

8971332270 ISUZU

INJECTION-PUMP ASSEMBLY
4BG1-T K 14BC INJECTION PUMP ASSY 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 9.1

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 86.5 85.4 87.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 475 475 475

Average injection quantity mm3/st. 9 7.6 10.4

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 130 125 135

Fixing the lever *

Rack limit *

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)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=6
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Speed control lever angle

F:Full speed I:Idle D:Dead point S:Stop
----------

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a=(29deg)+-5deg b=(13deg)+-5deg c=(22deg)+-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.
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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=14deg
----------
a=(100deg)

Information:

start by: a) remove fuel injection pump housing and governor1. Put the fuel injection pump housing on tool (A). 2. Remove bolts (1). 3. Remove bolt (2). Remove adapter housing (3) from the pump housing. 4. Remove bolts (4) and (5). Loosen bolt (6). 5. Remove governor housing (7) from the pump housing. 6. Remove spring (12), wave washer (11) and guide (10). Remove seat (8) and over fueling spring (9). 7. Pull shaft (13) up and remove it. Remove lever (14) from the housing. 8. Remove riser (follower) (17) from the shaft. Remove ring (15) and lever (16). 9. Remove cover (18) with tool (B). Tool (B) can cause damage to the cover. Always inspect the cover and install a new cover if needed.10. Install the timing pin to prevent the camshaft from turning. 11. Remove three bolts (19) that hold the flyweight assembly to the camshaft. Remove the flyweight assembly from the pump housing.12. Remove the timing pin.Connection Of Governor To Fuel Injection Pump Housing
1. Put the fuel injection pump housing on tool (A).2. Install the timing pin to prevent the camshaft from turning. 3. Put flyweight assembly (1) in position on the camshaft.
Be sure pin (2) that holds the shaft is in the correct position on back of the flyweight assembly.
4. Install new bolts for the flyweight assembly. The bolts for the flyweight assembly have a locking material on the threads and must not be used more than one time. 5. Install the cover over the flyweight assembly with tool (B). 6. Grind a taper on the bottom edge of a 1/8" screwdriver (3). Install the screwdriver through the bolt hole in the governor housing. The screwdriver must fit evenly against the flyweight assembly cover. Make a mark (stake) in four places around the cover in line with the groove in the camshaft.
Never install a used flyweight cover that is bent.
7. Install lever (4) on the dowel. Install ring (5). 8. Put riser (follower) (6) in position between the flyweights. Lift the flyweight up with a piece of wire and push the riser (follower) forward. 9. Put lever (10) in position. Lever (10) will be in the correct position when the lever end is in the groove of riser (follower) (6) and the ball end is engaged in sleeve shaft lever (9).
If lever (10) is not installed correctly, the governor can not operate and can cause the engine to over speed.
10. Install O-ring (7). Install shaft (8) to hold lever (10) in place. 11. Install over fueling spring (12) and seat (11) on the shaft. 12. Install guide (13), (wave) washer (14) and spring (15) in the governor housing.13. Put the governor housing on the fuel injection pump housing and install the bolts.end by: a) install adapter housing and leversb) install fuel injection pump housing and governorc) make adjustment of fuel system setting (See Fuel System Setting in Testing and Adjusting)