101402-7740 ZEXEL 9 400 611 878 BOSCH INJECTION-PUMP ASSEMBLY 9400611878 1014027740 8972514960

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 878 9400611878

ZEXEL 101402-7740 1014027740

ISUZU 8972514960 8972514960

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Buy INJECTION-PUMP ASSEMBLY 101402-7740 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-7740 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8980

3. GOVERNOR 105419-4280

4. SUPPLY PUMP 105220-6480

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:

101402-7740 as INJECTION-PUMP ASSEMBLY

106671-4810 as _

Cross reference number

BOSCH 9 400 611 878 9400611878

ZEXEL 101402-7740 1014027740

ISUZU 8972514960 8972514960

Zexel num

Bosch num

Firm num

Name

101402-7740

9 400 611 878

8972514960 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 8.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 77.5 76.4 78.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.1+-0.5

Pump speed r/min 435 435 435

Average injection quantity mm3/st. 10.5 9.1 11.9

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. 90 85 95

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting
----------
K=6
----------

Speed control lever angle

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

----------
a=3deg+-5deg b=15deg+-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:

preparatory step: a) remove oil pan1. Remove the suction screen mounting bolt.2. Remove the oil pump mounting bolts (1).3. Remove the oil pump-weight 40 lbs. (18,1 kg).Install Oil Pump
Prime the oil pump with SAE 30 engine oil before installation.
1. Position the oil pump on the engine, and install the pump mounting bolts and screen mounting bolt.concluding step: a) install oil panDisassemble Oil Pump
preparatory step: a) remove oil pump 1. Remove the oil pump idler gear (1). Using tool setup (A), remove the bearing from the gear.2. Remove the suction bell assembly (2) and relief valve oil tube (3). 3. Remove the relief valve (4) and spring (5).4. Using tool setup (B), pull the oil pump drive gear from the shaft. Remove the woodruff key. 5. Remove the oil pump housing cover (6).6. Remove the pump gears. 7. Using tool setup (C), remove the bearings from the pump housing and gear.8. Remove the bearing from the pump housing cover.Assemble Oil Pump
1. Using tool setup (A), install the bearing in the oil pump idler gear. Recess the bearing edge flush with the inner edge of the chamfer. 2. Using tool setup (B), install the bearings in the pump housing, pump gear and pump housing cover. Recess the bearing edge flush with the inner edge of the chamfer. 3. Lubricate the bearings, gears (1) and shaft with clean SAE 30 engine oil. Install the gears into the pump housing.4. Install the oil pump housing cover (2).5. Heat the oil pump drive gear to 350°F (177°C). Install the woodruff key and gear on the pump shaft.6. Install the relief valve and spring.7. Install the suction bell assembly, relief valve oil tube and install idler gear.concluding step: a) install oil pump