Information injection-pump assembly
BOSCH
9 400 613 991
9400613991
ZEXEL
101402-8280
1014028280
ISUZU
8973680960
8973680960
Rating:
Service parts 101402-8280 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
9 400 613 991
9400613991
ZEXEL
101402-8280
1014028280
ISUZU
8973680960
8973680960
Zexel num
Bosch num
Firm num
Name
101402-8280
9 400 613 991
8973680960 ISUZU
INJECTION-PUMP ASSEMBLY
4BG1-T K 14BD INJECTION PUMP ASSY PE4AD PE
4BG1-T K 14BD INJECTION PUMP ASSY 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=70mm
----------
a=20deg+-5deg b=11deg+-5deg c=35deg+-3deg
----------
aa=70mm
----------
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=8deg
----------
a=(100deg)
----------
aa=8deg
----------
a=(100deg)
Information:
Lubrication For A Rebuilt Engine
It is very important for a rebuilt engine to have "adequate" (needed) lubrication during the first seconds of operation. A "dry start" (without needed lubrication) on a rebuilt engine or an engine that has been in storage can cause bearing damage.To prevent the possibility of a "dry start" and bearing damage during the first few seconds of running, use the 1P0540 Flow Checking Tool Group and shop air pressure to pressure lubricate (fill the main oil passage with oil under pressure) all rebuilt engines and all engines that have been in storage.Procedure For Pressure Lubrication
1. Clean the tank of the 1P0540 Flow Checking Tool Group thoroughly, and set the pressure regulator to 240 35 kPa (35 5 psi).
Air pressure should not be more than 345 kPa (50 psi) at any time.
2. Put the correct engine oil into the tank. Use a minimum of 30% of the engine oil capacity. For some engines it will be necessary to fill the tank several times to get the correct amount of oil in the engine.3. Connect the tooling to the main oil passage of the engine.4. Add air pressure to the tank, with the regulator set at 240 35 kPa (35 5 psi). Although the tank has a hand pump, it is difficult to get enough air pressure to do the job with the hand pump. Therefore, use of shop air is recommended.5. Let the engine oil flow into the oil passage under pressure.Fill the crankcase with the correct engine oil. The amount of oil used in the pressure lubrication procedure must be subtracted from the recommended refill capacity in the Operation Maintenance Manual. If the engine is not going to be used for a long time, do the above procedure again before the first start.If shop air is not available, for charging the tank, the hand pump may be used to get the minimum required pressure.
DO NOT use the same 1P0540 Flow Checking Tool Group for both "pressure lubrication application" and for checking fuel flow. Incorrect cleaning is probable if the tool is used for both fuel and lubrication oil. Even a minute amount of dirt in the fuel system can cause fuel nozzle failure.
It is very important for a rebuilt engine to have "adequate" (needed) lubrication during the first seconds of operation. A "dry start" (without needed lubrication) on a rebuilt engine or an engine that has been in storage can cause bearing damage.To prevent the possibility of a "dry start" and bearing damage during the first few seconds of running, use the 1P0540 Flow Checking Tool Group and shop air pressure to pressure lubricate (fill the main oil passage with oil under pressure) all rebuilt engines and all engines that have been in storage.Procedure For Pressure Lubrication
1. Clean the tank of the 1P0540 Flow Checking Tool Group thoroughly, and set the pressure regulator to 240 35 kPa (35 5 psi).
Air pressure should not be more than 345 kPa (50 psi) at any time.
2. Put the correct engine oil into the tank. Use a minimum of 30% of the engine oil capacity. For some engines it will be necessary to fill the tank several times to get the correct amount of oil in the engine.3. Connect the tooling to the main oil passage of the engine.4. Add air pressure to the tank, with the regulator set at 240 35 kPa (35 5 psi). Although the tank has a hand pump, it is difficult to get enough air pressure to do the job with the hand pump. Therefore, use of shop air is recommended.5. Let the engine oil flow into the oil passage under pressure.Fill the crankcase with the correct engine oil. The amount of oil used in the pressure lubrication procedure must be subtracted from the recommended refill capacity in the Operation Maintenance Manual. If the engine is not going to be used for a long time, do the above procedure again before the first start.If shop air is not available, for charging the tank, the hand pump may be used to get the minimum required pressure.
DO NOT use the same 1P0540 Flow Checking Tool Group for both "pressure lubrication application" and for checking fuel flow. Incorrect cleaning is probable if the tool is used for both fuel and lubrication oil. Even a minute amount of dirt in the fuel system can cause fuel nozzle failure.
Have questions with 101402-8280?
Group cross 101402-8280 ZEXEL
Isuzu
101402-8280
9 400 613 991
8973680960
INJECTION-PUMP ASSEMBLY
4BG1-T
4BG1-T