101402-7922 ZEXEL 9 400 613 097 BOSCH INJECTION-PUMP ASSEMBLY 9400613097 1014027922 8972611772

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 097 9400613097

ZEXEL 101402-7922 1014027922

ISUZU 8972611772 8972611772

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Buy INJECTION-PUMP ASSEMBLY 101402-7922 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-7922 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8950

3. GOVERNOR 105411-2382

4. SUPPLY PUMP 105220-7560

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-4120

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5241

11. Nozzle and Holder 1-15300-421-0

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

13. NOZZLE-HOLDER 105030-4750

14. NOZZLE

105025-3730

15. NOZZLE SET

Include in #1:

101402-7922 as INJECTION-PUMP ASSEMBLY

106679-4153 as _

Cross reference number

BOSCH 9 400 613 097 9400613097

ZEXEL 101402-7922 1014027922

ISUZU 8972611772 8972611772

Zexel num

Bosch num

Firm num

Name

101402-7922

9 400 613 097

8972611772 ISUZU

INJECTION-PUMP ASSEMBLY
4BG1-T 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 4.2 4.15 4.25

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 10.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 95.5 94.4 96.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 81.3 81.3

Boost pressure mmHg 610 610

Injection quantity adjustment_02

Adjusting point -

Rack position 7.7+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 8.8 7.4 10.2

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point E

Rack position 10.8++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 120 115 125

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-1

Boost pressure kPa 20 16 24

Boost pressure mmHg 150 120 180

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(10.6)

Boost pressure kPa 68 61.3 74.7

Boost pressure mmHg 510 460 560

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)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting
----------
K=12 BCL=1+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=94mm
----------
a=20deg+-5deg b=11deg+-5deg c=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=32deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads. (B): Specified torque (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

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=7deg
----------
a=(100deg)

Information:

Before any service work is done on the fuel system, the outer surface of the injection pump housing must be clean.
Illustrations show fuel injection pump housing and governor removed from engine. Service work can be done with it installed on engine.1. Remove air bleed lines (2). 2. Remove bolts (1), flange (3), the flange assembly and the gaskets.3. Remove the bolts and the cover. 4. Remove bolts (5), solenoid (4) and the gasket.5. Remove two bolts (7) and fuel ratio control (6).6. Remove the shutoff housing from the cover. 7. Remove the bolts, lever (10) and shaft (8).8. Remove the bolts, lever (9) and shaft (11).9. Remove seal (12) from the shutoff housing. Install Shutoff Housing
1. Put 5S1454 Sealing Compound on the outside diameter of the seal and install the seal (1) with tooling (A) in the shutoff housing with the lip toward the outside. The outer face of the seal must be 1.0 mm (.039 in.) below the surface of the housing. Remove the extra sealing compound from the housing and the seal after installation. 2. Put shaft (5) in position in housing (4).3. Install lever (6) and the bolts. 4. Install shaft (2), lever (3) and the bolts. Make an alignment of the notch in shaft (2) with lever (3). 5. Put cover (7) in position on shutoff housing assembly (8) and install the bolts.6. Put fuel ratio control (10) in position and install the bolts. 7. Install the gasket, solenoid (9) and bolts on the cover.8. Put the cover in position and install the bolts.9. Install the gasket, flange assembly, gasket, flange (11) and the bolts.10. Connect air bleed lines (12).