Information injection-pump assembly
BOSCH
9 400 612 604
9400612604
ZEXEL
101402-8020
1014028020
ISUZU
8973187610
8973187610
Rating:
Service parts 101402-8020 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97211-280-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 612 604
9400612604
ZEXEL
101402-8020
1014028020
ISUZU
8973187610
8973187610
Zexel num
Bosch num
Firm num
Name
9 400 612 604
8973187610 ISUZU
INJECTION-PUMP ASSEMBLY
4JG1-T * K 14BC PE4A,5A, PE
4JG1-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
131424-0820
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
3.5
3.45
3.55
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
9.1
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
78.5
77.5
79.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
10
8
12
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
10.2++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
105
105
115
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)Idle sub spring setting: L1.
----------
K=8 L1=5.5-0.5mm
----------
----------
K=8 L1=5.5-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa
(2)When pump speed set at bb
(3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=5deg+-5deg b=0deg+-5deg c=15deg+-5deg
----------
aa=900r/min bb=750r/min
----------
a=5deg+-5deg b=0deg+-5deg c=15deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=3.5deg+-5deg b=53deg+-5deg
----------
----------
a=3.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'W' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=2deg
----------
a=(210deg)
----------
aa=2deg
----------
a=(210deg)
Information:
2. Remove guide (5), spring (4) and plunger (3) from the cover. 3. Remove O-ring seal (6) from the back of the cover. 4. Remove inner rotor (7) and outer rotor (8) from the timing gear cover. 5. Measure the inside diameter of bearing (9). The inside diameter must be 71.22 0.05 mm (2.804 .002 in.). Remove bearing (9) only if a replacement is necessary. Remove shaft (10) if a replacement is necessary. Install Oil Pump And Relief Valve
1. Thoroughly clean all of the parts. Put oil on all of the pump parts. 2. If the bearing was removed from the timing gear cover, install a new bearing with tool (A). Make sure the bearing is installed with the joint in the position shown in the illustration. 3. If the shaft was removed from the timing gear cover, install the new shaft so dimension "X" from the top of the shaft to the counterbore in the cover is 36.14 0.25 mm (1.423 .010 in.). 4. Install inner rotor (1) and outer rotor (2) in the timing gear cover.5. Measure the clearance between the rotors with a feeler gauge. The clearance must be 0.05 to 0.20 mm (.002 to .008 in.). The maximum permissible clearance is 0.28 mm (.011 in.). Make a replacement of BOTH rotors if the clearance is not correct. The rotors can not be ordered separately.6. Put plunger (3), spring (4) and guide (5) in the cover. Use a 1-1/8 in. crowfoot wrench and torque wrench to tighten guide (5) to a torque of 41 7 N m (30 5 lb.ft.). A slide rule type torque computer, Form No. SEHS7150, is available to find the torque wrench dial reading for different extensions. 7. Install O-ring seal (6) on the cover and put the cover in position on the timing gear cover. Install the locks and bolts that hold the cover in place. 8. Check the oil pump and clearance with a feeler gauge. The end clearance must be 0.069 to 0.135 mm (.0027 to .0053 in.). If the clearance is not correct, make a replacement of BOTH rotors or the cover.end by:a) install timing gear cover and oil pump.
1. Thoroughly clean all of the parts. Put oil on all of the pump parts. 2. If the bearing was removed from the timing gear cover, install a new bearing with tool (A). Make sure the bearing is installed with the joint in the position shown in the illustration. 3. If the shaft was removed from the timing gear cover, install the new shaft so dimension "X" from the top of the shaft to the counterbore in the cover is 36.14 0.25 mm (1.423 .010 in.). 4. Install inner rotor (1) and outer rotor (2) in the timing gear cover.5. Measure the clearance between the rotors with a feeler gauge. The clearance must be 0.05 to 0.20 mm (.002 to .008 in.). The maximum permissible clearance is 0.28 mm (.011 in.). Make a replacement of BOTH rotors if the clearance is not correct. The rotors can not be ordered separately.6. Put plunger (3), spring (4) and guide (5) in the cover. Use a 1-1/8 in. crowfoot wrench and torque wrench to tighten guide (5) to a torque of 41 7 N m (30 5 lb.ft.). A slide rule type torque computer, Form No. SEHS7150, is available to find the torque wrench dial reading for different extensions. 7. Install O-ring seal (6) on the cover and put the cover in position on the timing gear cover. Install the locks and bolts that hold the cover in place. 8. Check the oil pump and clearance with a feeler gauge. The end clearance must be 0.069 to 0.135 mm (.0027 to .0053 in.). If the clearance is not correct, make a replacement of BOTH rotors or the cover.end by:a) install timing gear cover and oil pump.