101402-7801 ZEXEL 9 400 613 493 BOSCH INJECTION-PUMP ASSEMBLY 9400613493 1014027801 8972574731

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 493 9400613493

ZEXEL 101402-7801 1014027801

ISUZU 8972574731 8972574731

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Buy INJECTION-PUMP ASSEMBLY 101402-7801 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-7801 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-4000

3. GOVERNOR 105419-4551

4. SUPPLY PUMP 105220-7140

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-9620

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5210

11. Nozzle and Holder 8-97257-496-0

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105025-2250

15. NOZZLE SET

Include in #1:

101402-7801 as INJECTION-PUMP ASSEMBLY

106672-9760 as _

Cross reference number

BOSCH 9 400 613 493 9400613493

ZEXEL 101402-7801 1014027801

ISUZU 8972574731 8972574731

Zexel num

Bosch num

Firm num

Name

101402-7801

9 400 613 493

8972574731 ISUZU

INJECTION-PUMP ASSEMBLY
4BG1 K 14BD INJECTION PUMP ASSY PE4AD 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 134424-4120

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.6 3.55 3.65

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 10

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 110 108.4 111.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 260 260 260

Average injection quantity mm3/st. 14 12.7 15.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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)Set idle sub-spring (4)Main spring setting
----------
K=12
----------

Speed control lever angle

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

----------
a=(15deg)+-5deg b=(29deg)+-5deg

Stop lever angle

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

----------
a=19deg+-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=20deg
----------
a=(95deg)

Information:

Illustration 8 g01455580
(6) 294-3395 Exhaust Support Assembly
Make four mounting holes for 294-3395 Exhaust Support Assembly (6) in the location (designated with a circle) which is shown in Illustration 8.
Illustration 9 g01456256
(17) 8T-4223 Hard Washers (18) 8T-4244 Nuts (19) 8T-4648 Bolt (20) 8T-4956 Bolt (21) 8T-6868 Bolts
Install exhaust support assembly (6) by using two 8T-6868 Bolts (21), one 8T-4648 Bolt (19), one 8T-4956 Bolt (20), four 8T-4223 Hard Washers (17), and four 8T-4244 Nuts (18). Refer to Illustration 9.
Illustration 10 g01456263
(9) 295-3044 Exhaust Support Groups (Lower half)
Remove the upper clamp from each 295-3044 Exhaust Support Group (9) by removing the two bolts and two hard washers. Keep the four bolts, the four hard washers, and the two upper clamps together. These parts will be reinstalled in Step 15.
Use four 8T-4956 Bolts (20) and four 8T-4223 Hard Washers (17) to install both 295-3044 Exhaust Support Groups (9) to exhaust support assembly (6). Refer to Illustration 10.
Illustration 11 g01456281
(5) 294-3065 Diesel Particulate Filter Group
To facilitate handling, remove the filter units from 294-3065 Diesel Particulate Filter Group (5) by removing the two clamps (including gaskets) closest to the rectangular intake manifold. Place the filter units, clamps, and gaskets aside.Note: Handle the removed filter units with extra care, as the internal structure is subject to damage due to impact, dropping, etc. Do not allow the inside of the filter units to get wet.
Install 294-3065 Diesel Particulate Filter Group (5) by aligning the mounting holes in the intake manifold with the mounting holes in the welded exhaust support assembly (7). Secure the intake manifold to the exhaust support assembly by using two 8T-4956 Bolts (20), two 8T-4223 Hard Washers (17), and two 8T-4244 Nuts (18). Refer to Illustration 11.
Reattach the lower filter unit to the intake manifold by reinstalling the clamp and the gasket that was removed in Step 12. Repeat for the upper filter unit.
Illustration 12 g01456285
Align the mounting holes in the upper half of 295-3044 Exhaust Support Group (9) with the mounting holes in the lower half of the exhaust support group (9). Reinstall the two bolts (9a) and the two hard washers (9b). Repeat for the other exhaust support group (9). Refer to Illustration 12.
Connect the straight end of exhaust tube assembly (8) to the manifold inlet pipe of the Diesel Particulate Filter Group. Use one 190-5341 Clamp (3)