Information injection-pump assembly
BOSCH
9 400 613 434
9400613434
ZEXEL
101402-8230
1014028230
ISUZU
8973645840
8973645840
Rating:
Service parts 101402-8230 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-394-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 434
9400613434
ZEXEL
101402-8230
1014028230
ISUZU
8973645840
8973645840
Zexel num
Bosch num
Firm num
Name
9 400 613 434
8973645840 ISUZU
INJECTION-PUMP ASSEMBLY
4BG1-T * K 14BD PE4AD PE
4BG1-T * K 14BD PE4AD 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
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
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
4.2
4.15
4.25
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
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.
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
----------
----------
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
----------
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)
----------
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)
----------
----------
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)
----------
aa=7deg
----------
a=(100deg)
Information:
Engine Runs Smoothly
Possible Causes/CorrectionsDirty Air Cleaner
If the air cleaner has a restriction indicator, see if the red piston is in view. If there is no restriction indicator, restriction can be checked with a water manometer or a vacuum gauge (which measures in inches of water). Make a connection to the piping between the air cleaner and the inlet of the turbocharger. Check with the engine running at full load rpm. Maximum restriction is 635 mm (25 in) of water. If a gauge is not available, visually check the air cleaner element for dirt. If the element is dirty, clean the element or install a new element.Air Inlet Piping Damage or Restriction
Make a visual inspection of the air inlet system and check for damage to piping, rags in the inlet piping, or damage to the rain cap or the cap pushed too far on the inlet pipe. If no damage is seen, check inlet restriction with a clean air cleaner element.Exhaust System Restriction
Make a visual inspection of the exhaust system. Check for damage to piping or for a bad muffler. If no damage is found, you can check the system by checking the back pressure from the exhaust (pressure difference measurement between exhaust outlet and atmosphere). The back pressure must not be more than 1016 mm (40 in) of water. You can also check by removing the exhaust pipes from the exhaust manifolds. With the exhaust pipes removed, start and load the engine on a chassis dynamometer to see if the problem is corrected.Fuel Injection Timing Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual.Fuel Setting Is Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. See the Fuel Setting And Related Information Fiche for the correct fuel setting.Low Quality Fuel
Test the engine with fuel according to recommendations by Caterpillar Inc. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines. Also, Special Instruction, Form No. SEHS6947 has fuel correction factors and tables.Bad Fuel Nozzle(s)
Bad fuel nozzles will normally cause the engine to misfire and run rough, but can cause too much smoke with engine still running smooth. Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual.Wrong Seal Washer Installed Under Nozzle(s)
The use of incorrect washers change the location of the fuel injection nozzles in the combustion chamber. This effects smoke. Check the Engine Arrangement for the correct part number to use.Valve Adjustment Not Correct or Valve Leakage
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in) and exhaust valve clearance is 0.76 mm (.030 in). Valve leakage normally causes the engine to misfire and run rough.Bad Fuel Injection Pump
An injection pump can have a good fuel flow coming from it but cause rough running because of slow timing that is caused by wear on the bottom end of the
Possible Causes/CorrectionsDirty Air Cleaner
If the air cleaner has a restriction indicator, see if the red piston is in view. If there is no restriction indicator, restriction can be checked with a water manometer or a vacuum gauge (which measures in inches of water). Make a connection to the piping between the air cleaner and the inlet of the turbocharger. Check with the engine running at full load rpm. Maximum restriction is 635 mm (25 in) of water. If a gauge is not available, visually check the air cleaner element for dirt. If the element is dirty, clean the element or install a new element.Air Inlet Piping Damage or Restriction
Make a visual inspection of the air inlet system and check for damage to piping, rags in the inlet piping, or damage to the rain cap or the cap pushed too far on the inlet pipe. If no damage is seen, check inlet restriction with a clean air cleaner element.Exhaust System Restriction
Make a visual inspection of the exhaust system. Check for damage to piping or for a bad muffler. If no damage is found, you can check the system by checking the back pressure from the exhaust (pressure difference measurement between exhaust outlet and atmosphere). The back pressure must not be more than 1016 mm (40 in) of water. You can also check by removing the exhaust pipes from the exhaust manifolds. With the exhaust pipes removed, start and load the engine on a chassis dynamometer to see if the problem is corrected.Fuel Injection Timing Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual.Fuel Setting Is Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. See the Fuel Setting And Related Information Fiche for the correct fuel setting.Low Quality Fuel
Test the engine with fuel according to recommendations by Caterpillar Inc. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines. Also, Special Instruction, Form No. SEHS6947 has fuel correction factors and tables.Bad Fuel Nozzle(s)
Bad fuel nozzles will normally cause the engine to misfire and run rough, but can cause too much smoke with engine still running smooth. Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual.Wrong Seal Washer Installed Under Nozzle(s)
The use of incorrect washers change the location of the fuel injection nozzles in the combustion chamber. This effects smoke. Check the Engine Arrangement for the correct part number to use.Valve Adjustment Not Correct or Valve Leakage
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in) and exhaust valve clearance is 0.76 mm (.030 in). Valve leakage normally causes the engine to misfire and run rough.Bad Fuel Injection Pump
An injection pump can have a good fuel flow coming from it but cause rough running because of slow timing that is caused by wear on the bottom end of the