101402-7640 ZEXEL 9 400 611 814 BOSCH INJECTION-PUMP ASSEMBLY 9400611814 1014027640 8972222350

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 814 9400611814

ZEXEL 101402-7640 1014027640

ISUZU 8972222350 8972222350

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Buy INJECTION-PUMP ASSEMBLY 101402-7640 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-7640 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8900

3. GOVERNOR 105419-4040

4. SUPPLY PUMP 105220-6250

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-2520

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5130

11. Nozzle and Holder 8-97222-170-0

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

13. NOZZLE-HOLDER 105030-4750

14. NOZZLE

105025-3040

15. NOZZLE SET

Include in #1:

101402-7640 as INJECTION-PUMP ASSEMBLY

106671-2310 as _

Cross reference number

BOSCH 9 400 611 814 9400611814

ZEXEL 101402-7640 1014027640

ISUZU 8972222350 8972222350

Zexel num

Bosch num

Firm num

Name

101402-7640

9 400 611 814

8972222350 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 8.4

Pump speed r/min 1100 1100 1100

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. 8.8 7.4 10.2

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: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=10
----------

Speed control lever angle

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

----------
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=13deg+-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=10deg
----------
a=(100deg)

Information:

TIMING MARKS2. Remove the plug from the timing pin hole in fuel injection pump housing and install timing pin (1).
TIMING PIN INSTALLED
1. FT887 Timing Pin (Fabricated Tool).3. Remove the tachometer drive adapter shaft (2).
TACHOMETER DRIVE ADAPTER
2. Tachometer drive adapter shaft.4. Using puller group (3), remove the fuel injection pump camshaft drive gear as follows. Thread the 9S8528 Bolt Assembly into the fuel injection pump camshaft. Do not force the bolt assembly. It should thread easily. Install the 9S8527 Bolt by threading it into the drive gear. Then tighten the 9S8527 Bolt with a wrench until the gear "pops" loose. Remove the gear (4) and the tool setup.
9S8520 PULLER GROUP INSTALLED
3. 9S8520 Puller Group.
REMOVING GEAR
4. Gear.5. Remove retaining screw (5), washer (6), and automatic timing advance (7) from the engine camshaft.
TIMING ADVANCE
5. Retaining screw. 6. Washer. 7. Automatic timing advance.6. Install puller (8), with spacer (10) over the shaft in the camshaft and spacer (9) on spacer (10) as shown and remove the gear from the camshaft.
REMOVING GEAR (Typical Example)
8. 1P2321 Puller. 9. 8S5579 Spacer. 10. 9S9155 Spacer.Install Camshaft Gear
1. Heat the gear to a temperature of approximately 400° F (204° C) before installing on the camshaft.
Do not heat the gear with a torch. Do not heat the gear to a temperature of more than 600° F (315° C). Heating the gear with a torch or to a temperature of more than 600° F (315° C) may cause the two drive dowels for the automatic timing advance to loosen and come out of the gear.
2. Align slot in gear hub with the pin in the camshaft. Install the gear on the camshaft with timing mark on gear aligned with timing mark on crankshaft gear. Be sure the gear is completely seated against the shoulder of the camshaft.
TIMING MARKS
Do not drive the gear on the camshaft. Serious damage can result to camshaft or camshaft thrust pin.
3. Align holes in weights with dowels in gear and install the automatic timing advance.4. Align pin (11) in washer (6) with hole (12) in camshaft and install washer (6).
INSTALLING WASHER
6. Washer. 11. Pin. 12. Hole.5. Install retaining screw (5) and tighten to 108 36 lb. in. (124.5 41.5 cm.kg). Stake screw (5) in two places.
Stake retaining screw (5) carefully. Heavy blows on washer or retaining screw can force the shaft extension too far into the camshaft and eliminate all end clearance.
STAKING SCREW (Typical Example)
5. Retaining screw.6. After retaining screw (5) is staked, the gear and weight assembly requires .003 to .027 in. (0.08 to 0.69 mm) end clearance to prevent binding against the washer, camshaft end, or camshaft gear.7. Position the drive gear on the fuel injection pump camshaft.8. Install the tachometer drive adapter shaft and tighten the shaft retaining nut to 32 2 lb. ft. (4.4 0.3 mkg).9. Remove the timing pin from the fuel injection pump housing and install the plug in the timing hole.