101402-8231 ZEXEL 9 400 613 494 BOSCH INJECTION-PUMP ASSEMBLY 9400613494 1014028231 8973645841

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 494 9400613494

ZEXEL 101402-8231 1014028231

ISUZU 8973645841 8973645841

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Buy INJECTION-PUMP ASSEMBLY 101402-8231 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-8231 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-4150

3. GOVERNOR 105411-2790

4. SUPPLY PUMP 105220-7570

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-4120

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5120

11. Nozzle and Holder 1-15300-394-0

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

13. NOZZLE-HOLDER 105030-4750

14. NOZZLE 105025-3030

15. NOZZLE SET

Include in #1:

101402-8231 as INJECTION-PUMP ASSEMBLY

106674-4067 as _

Cross reference number

BOSCH 9 400 613 494 9400613494

ZEXEL 101402-8231 1014028231

ISUZU 8973645841 8973645841

Zexel num

Bosch num

Firm num

Name

101402-8231

9 400 613 494

8973645841 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 10.9

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 104 102.9 105.1

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 82.6 82.6

Boost pressure mmHg 620 620

Injection quantity adjustment_02

Adjusting point -

Rack position 7.7+-0.5

Pump speed r/min 650 650 650

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 11.1++

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 R1-0.95

Boost pressure kPa 23.3 19.3 27.3

Boost pressure mmHg 175 145 205

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(10.9)

Boost pressure kPa 69.3 62.6 76

Boost pressure mmHg 520 470 570

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)Rack difference between N = N1 and N = N2 (5)Boost compensator stroke: BCL (6)Set idle sub-spring (7)Main spring setting
----------
K=13 N1=1200r/min N2=350r/min BCL=0.95+-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=19deg+-5deg b=11deg+-5deg c=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)(Seal at delivery.) (3)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:

White Smoke
Possible Causes/CorrectionsCold Outside Temperatures
When the air outside is cold, the cylinder temperature is cooler. Not all the fuel will burn in the cylinders. The fuel which does not burn comes out the exhaust as white smoke. White smoke is normal in cold temperatures until the engine operates long enough to become warm. There will be less white smoke if No. 1 diesel fuel is used.Long Idle Periods
When an engine runs at idle speed for a long period of time, the cylinders cool and all of the fuel does not burn. Do not idle an engine for a long period of time. Stop an engine when it is not in use. If long idle periods are necessary, use No. 1 diesel fuel.Engine Operating Temperature Too Low
This can cause white smoke on startup. If the smoke is slow to clear from the exhaust, check and make a replacement of the thermostat if needed.Low Quality Fuel
Test the engine using fuec according to recommendations by Caterpillar Inc. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines.Air In Fuel System
With air in the fuel system, the engine will normally be difficult to start, run rough, and release a large amount of white smoke. If the engine will not start, loosen a fuel injection line nut at the through the head adapter and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine still does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the through head adapters until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air cannot be removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leakage at the connections between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. If there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.Fuel Injection Timing Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual.Valve Adjustment Not Correct
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).Bad Fuel Nozzle(s)
Bad fuel nozzles will normally cause the engine to "misfire" and run rough, but can cause too much smoke with the engine still running smooth. Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual.Misfiring Cylinder(s)
See Misfiring And Running Rough.Coolant Leakage Into Combustion Chamber
Coolant in the combustion chamber can