Information injection-pump assembly
BOSCH
9 400 613 990
9400613990
ZEXEL
101402-8270
1014028270
ISUZU
8973639890
8973639890
Rating:
Service parts 101402-8270 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 990
9400613990
ZEXEL
101402-8270
1014028270
ISUZU
8973639890
8973639890
Zexel num
Bosch num
Firm num
Name
9 400 613 990
8973639890 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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
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
10.4
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
90
88.9
91.1
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
475
475
475
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
10.6++
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
550
550
550
Rack position
8.9
Boost pressure
kPa
33.3
29.3
37.3
Boost pressure
mmHg
250
220
280
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
9.45
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)Boost compensator stroke: BCL
(5)Set idle sub-spring
(6)Main spring setting
(7)Rack difference between N = N1 and N = N2
----------
K=10 BCL=0.55+-0.1mm N1=1100r/min N2=550r/min
----------
----------
K=10 BCL=0.55+-0.1mm N1=1100r/min N2=550r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=70mm
----------
a=5deg+-5deg b=20deg+-5deg
----------
aa=70mm
----------
a=5deg+-5deg b=20deg+-5deg
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)
----------
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=11deg
----------
a=(100deg)
----------
aa=11deg
----------
a=(100deg)
Information:
Outside Leaks
Possible Causes/CorrectionsLeaks in Hoses or Connections
Check all hoses and connections for visual signs of leakage. If no leaks are seen, look for damage to hoses or loose clamps.Leaks in the Radiator and/or Expansion Tank
Put pressure to the radiator and/or expansion tank with the 9S8140 Cooling System Pressurizing Pump Group and check for leaks.Leaks in the Heater
Put pressure to the cooling system with the 9S8140 Cooling System Pressurizing Pump Group and check the heater for leaks.Leaks in the Water Pump
Check the water pump for leaks before starting the engine, then start the engine and look for leaks. If there are leaks at the water pump, repair or install a new water pump.Cylinder Head Gasket Leakage
Look for leaks along the surface of the cylinder head gasket. If you see leaks, install a new head gasket.Coolant Leaks At The Overflow Tube
Possible Causes/CorrectionsBad Pressure Cap or Relief Valve
Check the sealing surfaces of the pressure cap and the radiator to be sure the cap is sealing correctly. Check the opening pressure and sealing ability of the pressure cap or relief valve with the 9S8140 Cooling System Pressurizing Pump Group.Engine Runs Too Hot
If coolant temperature is too high, pressure will be high enough to move the cap off of the sealing surface in the radiator and cause coolant loss through the overflow tube. See "Overheating" in Cooling System Troubleshooting section.Expansion Tank Too Small or Installed Wrong
The expansion tank can be either a part of the radiator or it can be installed separately from the radiator. The expansion tank must be large enough to hold the expansion of the coolant as it gets warm or has sudden changes in pressure. Make sure the expansion tank is installed correctly, and the size is according to the recommendations of the truck manufacturer.Cylinder Head Gasket Leakage or Crack(s) in Cylinder Head or Cylinder Block
Remove the radiator cap and, with the engine running, look for air bubbles in the coolant. Bubbles in the coolant are a sign of probable leakage at the head gasket. Remove the cylinder head from the engine. Check cylinder head, cylinder walls and head gasket surface of the cylinder block for cracks. When the head is installed, use a new head gasket, spacer plate gasket, water seals, and O-ring seals.Inside Leakage
Possible Causes/CorrectionsCylinder Head Gasket Leakage
If the cylinder head gasket leaks between a water passage and an opening into the crankcase, coolant will get into the crankcase.Crack(s) in Cylinder Head
Crack(s) in the upper surface of the cylinder head, or an area between a water passage and an opening into the crankcase, can allow coolant to get into the crankcase.Crack(s) in Cylinder Block
Crack(s) in the cylinder block between a water passage and the crankcase will let coolant get into the crankcase.
Possible Causes/CorrectionsLeaks in Hoses or Connections
Check all hoses and connections for visual signs of leakage. If no leaks are seen, look for damage to hoses or loose clamps.Leaks in the Radiator and/or Expansion Tank
Put pressure to the radiator and/or expansion tank with the 9S8140 Cooling System Pressurizing Pump Group and check for leaks.Leaks in the Heater
Put pressure to the cooling system with the 9S8140 Cooling System Pressurizing Pump Group and check the heater for leaks.Leaks in the Water Pump
Check the water pump for leaks before starting the engine, then start the engine and look for leaks. If there are leaks at the water pump, repair or install a new water pump.Cylinder Head Gasket Leakage
Look for leaks along the surface of the cylinder head gasket. If you see leaks, install a new head gasket.Coolant Leaks At The Overflow Tube
Possible Causes/CorrectionsBad Pressure Cap or Relief Valve
Check the sealing surfaces of the pressure cap and the radiator to be sure the cap is sealing correctly. Check the opening pressure and sealing ability of the pressure cap or relief valve with the 9S8140 Cooling System Pressurizing Pump Group.Engine Runs Too Hot
If coolant temperature is too high, pressure will be high enough to move the cap off of the sealing surface in the radiator and cause coolant loss through the overflow tube. See "Overheating" in Cooling System Troubleshooting section.Expansion Tank Too Small or Installed Wrong
The expansion tank can be either a part of the radiator or it can be installed separately from the radiator. The expansion tank must be large enough to hold the expansion of the coolant as it gets warm or has sudden changes in pressure. Make sure the expansion tank is installed correctly, and the size is according to the recommendations of the truck manufacturer.Cylinder Head Gasket Leakage or Crack(s) in Cylinder Head or Cylinder Block
Remove the radiator cap and, with the engine running, look for air bubbles in the coolant. Bubbles in the coolant are a sign of probable leakage at the head gasket. Remove the cylinder head from the engine. Check cylinder head, cylinder walls and head gasket surface of the cylinder block for cracks. When the head is installed, use a new head gasket, spacer plate gasket, water seals, and O-ring seals.Inside Leakage
Possible Causes/CorrectionsCylinder Head Gasket Leakage
If the cylinder head gasket leaks between a water passage and an opening into the crankcase, coolant will get into the crankcase.Crack(s) in Cylinder Head
Crack(s) in the upper surface of the cylinder head, or an area between a water passage and an opening into the crankcase, can allow coolant to get into the crankcase.Crack(s) in Cylinder Block
Crack(s) in the cylinder block between a water passage and the crankcase will let coolant get into the crankcase.