101402-7530 ZEXEL 9 400 611 312 BOSCH INJECTION-PUMP ASSEMBLY 9400611312 1014027530 8972229760

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 312 9400611312

ZEXEL 101402-7530 1014027530

ISUZU 8972229760 8972229760

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Buy INJECTION-PUMP ASSEMBLY 101402-7530 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-7530 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8710

3. GOVERNOR 105419-2100

4. SUPPLY PUMP 105220-6340

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-8420

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4480

11. Nozzle and Holder 8-97134-842-0

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

13. NOZZLE-HOLDER 105030-4750

14. NOZZLE

105025-0290

15. NOZZLE SET

Include in #1:

101402-7530 as INJECTION-PUMP ASSEMBLY

101803-1170 as _

Cross reference number

BOSCH 9 400 611 312 9400611312

ZEXEL 101402-7530 1014027530

ISUZU 8972229760 8972229760

Zexel num

Bosch num

Firm num

Name

101402-7530

9 400 611 312

8972229760 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 3.2 3.15 3.25

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 8.9

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 88 86.9 89.1

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 650 650 650

Average injection quantity mm3/st. 11.5 10.1 12.9

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. 165 160 170

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=7
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(6deg)+-5deg b=(21deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=4.5deg+-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=12deg
----------
a=(100deg)

Information:

INJECTION NOZZLE (Right side illustrated)
1. Lines (eight, four each side). 2. Injection nozzles (eight, four each side). 3. Clamps (eight, four each side).4. Remove the adapter (4) and lift injection nozzle (2) out of the cylinder head.
ADAPTER AND NOZZLE REMOVAL
2. Injection nozzle. 4. Adapter. 5. O-ring seal. 6. O-ring seal.
Pull nozzle straight out, by hand, to remove. Slight twisting action is permissible if necessary. Never pry out a nozzle with a screwdriver or other similar tool.
Always replace O-ring seals (5) and (6) before installing nozzle.5. Use needle-nose pliers to remove carbon seal dam (8). Always install a new compression seal (7) and carbon seal dam (8) before installing injection nozzle.
REMOVING CARBON SEAL DAM (Typical Example)
7. Compression seal. 8. Carbon seal dam.Install Fuel Injection Nozzles
1. Be sure the bore in the cylinder head and fuel inlet fittings are clean.
Never install an injection nozzle that has been dropped, without first testing it with the 8S2242 Nozzle Tester Group. The injector tips are very hard and brittle and break easily.
2. Install a new compression seal and carbon seal dam. Use carbon seal dam installation tool (9) to install the carbon seal dam.
INSTALLING CARBON SEAL DAM (Typical Example)
9. 8S2252 Carbon Seal Dam Installation Tool.3. Install a new O-ring seal (6) on the injection nozzle (2) and a new O-ring seal (5) on the adapter (4).4. Install the injection nozzle (2) into the cylinder head using a twisting motion. Do not use lubricant in the cylinder head bore or on the nozzle body.
INSTALLING NOZZLE
2. Injection nozzle. 4. Adapter. 5. O-ring seal. 6. O-ring seal.
Do not bend the injector inlet connection when installing injector into cylinder head. Bending of the inlet connection creates tension on the injector and causes binding of the needle in the guide.
5. Install the adapter (4) and tighten the injection nozzle-to-adapter retaining nut. Tighten retaining nut to 30 5 lb. ft. (4.1 0.7 mkg). Hand tighten the fuel injection line.6. Install the injection nozzle clamp.7. Install the fuel return manifold and rocker arm assembly. Install retaining bolts and locks. Tighten bolts to 18 5 lb. ft. (2.5 0.7 mkg) and bend locks.8. Adjust the intake valve clearance to .015 in. (0.38 mm) and the exhaust valve clearance to .025 in. (0.64 mm).9. Install valve cover. Install mounting bolts and tighten to 120 24 lb. in. (138 28 cm.kg).10. Purge the fuel lines of air by motoring the engine until fuel, free of air, flows from the connections.11. Use 5P144 Fuel Line Socket to tighten the fuel line connections to 30 5 lb. ft. (4.1 0.7 mkg).12. Start the engine and correct any fuel leaks that may occur.