101402-7540 ZEXEL 9 400 611 575 BOSCH INJECTION-PUMP ASSEMBLY 9400611575 1014027540 8972216540

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 575 9400611575

ZEXEL 101402-7540 1014027540

ISUZU 8972216540 8972216540

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Buy INJECTION-PUMP ASSEMBLY 101402-7540 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-7540 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8311

3. GOVERNOR 105419-3430

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:

101402-7540 as INJECTION-PUMP ASSEMBLY

101801-1860 as _

Cross reference number

BOSCH 9 400 611 575 9400611575

ZEXEL 101402-7540 1014027540

ISUZU 8972216540 8972216540

Zexel num

Bosch num

Firm num

Name

101402-7540

9 400 611 575

8972216540 ISUZU

INJECTION-PUMP ASSEMBLY
4BG1 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 8.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 80 78.9 81.1

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 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. 125 120 130

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: +-0.05 (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=9
----------

Speed control lever angle

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

----------
a=(21deg)+-5deg b=(17deg)+-5deg c=(18deg)+-5deg d=(13deg)+-3deg

Stop lever angle

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

----------
a=6deg+-5deg b=46deg+-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=15deg
----------
a=(100deg)

Information:

Use extreme care in keeping the work area and tools clean. Handle all parts with care to avoid any damage.
1. Place the nozzle in the holding tool (2) and secure the tool in a vise. Do not clamp any part of the nozzle body directly in the vise.
LOOSENING LOCKNUT
1. Locknut. 2. 8S2250 Nozzle Holding Tool.2. Loosen lift adjusting screw locknut (1). Loosen the lift adjusting screw two or three turns. Loosen pressure screw (3).
LOOSENING PRESSURE SCREW
3. Pressure screw.
PRESSURE SCREW ASSEMBLY REMOVED3. Holding the nozzle in one hand, invert it and back out the pressure screw allowing the spring, spring seat and shims to fall into your hand. The valve may slide out, by its own weight, and should be handled carefully by its stem.4. If the valve does not fall out, remove it with retractor (4). To prevent bending the valve, bottom it in the body with the retractor. Push down on the retractor body to mount the collet. Turn the knurled nut counterclockwise to secure the collet and withdraw the valve.
REMOVING VALVE
4. 5P958 Valve Retractor.5. Place the parts in solvent to loosen carbon and deposits of foreign material. Do not soak the body assembly in solvent for over 1 to 2 hours. The solvent can damage the epoxy bond used to secure the body assembly components together.Assemble Fuel Injection Nozzle (9L7883 Nozzles)
Before assembly, wash all parts thoroughly. Flush the body to remove any debris or lapping compound. Assemble while all parts are wet with clean fuel.1. Handle valve (1) by its shank and slide it partially into the body.
ASSEMBLENG NOZZLE
1. Valve. 2. Spring seat. 3. Spring. 4. Shims. 5. Pressure screw. 6. Locknut. 7. Lift adjusting screw.2. Assemble lift adjusting screw (7) into pressure screw (5) two to three turns and install locknut (6), do not tighten the locknut. Put shims (4), spring (3), and spring seat (2) on the lift adjusting screw. Put the thickest shim (4) against the screw.3. Tilt the nozzle body and with spring seat (2) in contact with the top of valve (1), push the valve and spring components into the body and tighten the pressure screw hand tight.4. Put the nozzle in the 8S2250 Nozzle Holding Tool. Put the holding tool in a vise and tighten the pressure screw (5) to 75 to 80 lb. in. (86.5 to 92.2 cm.kg).
TIGHTENING PRESSURE SCREW To check or adjust the opening pressure and the valve lift see the TESTING AND ADJUSTING section of the Service Manual.5. To tighten the locknut, hold lift adjusting screw (7) with a screwdriver and tighten the locknut (6) just enough so lift adjusting screw (7) will not turn.
TIGHTENING LOCKNUT6. Use a torque wrench and tighten the locknut to 35 to 40 lb. in. (40.4 to 46.1 cm.kg).
TIGHTENING LOCKNUTService And Inspect Fuel Injection Nozzle (9L7883 Nozzles)
1. Use the brush (4) to clean the tip and body exterior.2. Secure the 8S2247 Cleaning Wire [.008 to .009 in. (0.20 to 0.23 mm) dia.] in pin vise (1) with 1/32 in. (0.79 mm)