Information injection-pump assembly
BOSCH
9 400 613 980
9400613980
ZEXEL
101402-7760
1014027760
ISUZU
8972544290
8972544290
Rating:
Service parts 101402-7760 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97222-170-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 980
9400613980
ZEXEL
101402-7760
1014027760
ISUZU
8972544290
8972544290
Zexel num
Bosch num
Firm num
Name
9 400 613 980
8972544290 ISUZU
INJECTION-PUMP ASSEMBLY
4BG1-T * K 14BC PE4A,5A, PE
4BG1-T * K 14BC PE4A,5A, PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-4920
Overflow valve opening pressure
kPa
127
127
127
Overflow valve opening pressure
kgf/cm2
1.3
1.3
1.3
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.8
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
94
92.9
95.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.1+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
8.8
7.4
10.2
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
9++
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=6
----------
----------
K=6
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=2deg+-5deg b=21deg+-5deg
----------
----------
a=2deg+-5deg b=21deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=4.5deg+-5deg b=53deg+-5deg
----------
----------
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=9deg
----------
a=(100deg)
----------
aa=9deg
----------
a=(100deg)
Information:
preparatory steps: a) remove timing gear coverb) remove fuel injection pump housing and governorc) remove fuel transfer pump 1. Disconnect the accessory drive oil supply line (1) and the fuel drain line (2). Remove the fuel priming pump.2. Remove the accessory drive shaft gear retaining nut, washer, and sleeve. 3. Using tool (A), remove the accessory drive gear. 4. Remove four retaining bolts (3), two locks and retainer (4).5. Remove the accessory drive housing.6. Remove the accessory drive shaft and bearing as a unit from the housing. 7. Using tool (B), remove bearing (5).Install Accessory Drive Shaft
1. Heat the accessory drive shaft bearing to 300°F (149°C) and install the bearing on the shaft. 2. Install the accessory drive shaft and bearing (1) in the housing.3. Install the accessory drive housing. 4. Install the retainer, locks and retaining bolts.5. Locate top center (TC) compression stroke for No. 1 piston. See LOCATING TOP CENTER COMPRESSION POSITION FOR No. 1 PISTON in TESTING AND ADJUSTING. 6. Rotate the accessory drive shaft until tool (A) can be installed. 7. Install the accessory drive shaft sleeve, drive gear, conical washer and nut. Install the conical washer on the drive shaft with the O.D. in contact with the gear. Tighten the retaining nut (2) to 100 10 lb. ft. (13,8 1,4 mkg).8. Connect the fuel drain line and the oil supply line. Install the fuel priming pump.concluding steps: a) install fuel transfer pumpb) install fuel injection pump housing and governorc) install timing gear cover
1. Heat the accessory drive shaft bearing to 300°F (149°C) and install the bearing on the shaft. 2. Install the accessory drive shaft and bearing (1) in the housing.3. Install the accessory drive housing. 4. Install the retainer, locks and retaining bolts.5. Locate top center (TC) compression stroke for No. 1 piston. See LOCATING TOP CENTER COMPRESSION POSITION FOR No. 1 PISTON in TESTING AND ADJUSTING. 6. Rotate the accessory drive shaft until tool (A) can be installed. 7. Install the accessory drive shaft sleeve, drive gear, conical washer and nut. Install the conical washer on the drive shaft with the O.D. in contact with the gear. Tighten the retaining nut (2) to 100 10 lb. ft. (13,8 1,4 mkg).8. Connect the fuel drain line and the oil supply line. Install the fuel priming pump.concluding steps: a) install fuel transfer pumpb) install fuel injection pump housing and governorc) install timing gear cover