101402-7720 ZEXEL 9 400 611 815 BOSCH INJECTION-PUMP ASSEMBLY 9400611815 1014027720 8972490840

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 815 9400611815

ZEXEL 101402-7720 1014027720

ISUZU 8972490840 8972490840

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Buy INJECTION-PUMP ASSEMBLY 101402-7720 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-7720 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8900

3. GOVERNOR 105419-4150

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:

101402-7720 as INJECTION-PUMP ASSEMBLY

106672-9890 as _

Cross reference number

BOSCH 9 400 611 815 9400611815

ZEXEL 101402-7720 1014027720

ISUZU 8972490840 8972490840

Zexel num

Bosch num

Firm num

Name

101402-7720

9 400 611 815

8972490840 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 8.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 87 85.9 88.1

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=13
----------

Speed control lever angle

F:Full speed I:Idle S:Stop D:Dead point (1)Stopper bolt setting
----------

----------
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:

1. Locate top center (TC) compressing stroke for No. 1 piston. See LOCATING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING. 2. Install the timing fixture plate (A), on the rear face of the accessory drive shaft housing.3. If the plate can be installed with the dowels in the accessory drive shaft housing aligned with the dowel holes in the plate, the accessory drive shaft is correctly timed. Proceed to Step 8. If the plate cannot be installed, continue with Step 4. 4. Remove the cover (1) from the front of the timing gear cover. Remove the accessory drive gear retaining nut and washer. 5. Using tool (B), separate the gear from the accessory drive shaft. Rotate the accessory drive shaft until the timing fixture plate (A) can be installed.6. Install the conical washer on the drive shaft with the O.D. in contact with the gear. Install and tighten the retaining nut to 100 10 lb. ft. (13,8 1,4 mkg). 7. Install the cover (1) on the timing gear cover, and remove the timing fixture plate.8. Position the fuel injection pump housing and governor on the engine, and install the mounting bolts.9. Connect the fuel injection lines and tighten the retaining nut to 30 5 lb. ft. (4,1 0,7 mkg).10. Connect the fuel ratio control sensing line.11. Connect the turbocharger oil supply line and clamp.12. Connect the governor control linkage.
When the governor control linkage is connected the spring tension must hold the governor control lever towards the OFF position.
Separate Governor From Fuel Injection Pump Housing
preparatory steps: a) remove fuel injection pump housing and governor as a unitb) remove fuel ratio control1. Remove idle screw housing plate assembly, and shut down solenoid. 2. Remove two retaining bolts (3) and remove the solenoid fuel shutoff lever (4).3. Remove the idle screw cover (1).4. Remove idle screw housing (2).5. Remove the rack stop collar retaining screw (7). 6. Remove the rack stop collar (5), collar (8), and spring (6).7. Remove the governor-to-fuel injection pump housing mounting bolts (9). 8. Remove the governor housing (10).9. Remove the governor spring (13), seat assembly (11), and washer-type spring. 10. Remove the three mounting bolts (12) and lock that secure the cylinder and weight assemblies (14) to the fuel injection pump housing.11. Pull the cylinder and weight assemblies straight out to clear locating dowels.12. Move the cylinder and weight assemblies sideways to disengage slot in piston from the rack (15).Connect Governor To Fuel Injection Pump Housing
1. Position the cylinder and weight assemblies (1) on the fuel injection pump housing so slot in piston is engaged with the rack (2).2. Push the cylinder and weight assemblies onto the locating dowels. 3. Install the three mounting bolts (5) and lock.4. Install the washer-type spring, seat assembly (4), and governor spring (6) on the cylinder assembly. The washer-type spring should be installed so the outside diameter of spring will contact the guide in governor housing (3).5. Position the governor housing