101402-9040 ZEXEL 9 400 613 993 BOSCH INJECTION-PUMP ASSEMBLY 9400613993 1014029040 12742051012

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 993 9400613993

ZEXEL 101402-9040 1014029040

YANMAR 12742051012 12742051012

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Buy INJECTION-PUMP ASSEMBLY 101402-9040 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-9040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8110

3. GOVERNOR 105400-1630

4. SUPPLY PUMP 105220-4300

5. AUTOM. ADVANCE MECHANIS 105622-0590

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-9040 as INJECTION-PUMP ASSEMBLY

106679-4045 as _

Cross reference number

BOSCH 9 400 613 993 9400613993

ZEXEL 101402-9040 1014029040

YANMAR 12742051012 12742051012

Zexel num

Bosch num

Firm num

Name

101402-9040

9 400 613 993

12742051012 YANMAR

INJECTION-PUMP ASSEMBLY
4H25 K 14BC INJECTION PUMP ASSY PE4A,5A, 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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-4-3

Pre-stroke mm 3 2.95 3.05

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 9.8

Pump speed r/min 1400 1400 1400

Each cylinder's injection qty mm3/st. 66 64.3 67.7

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 6+-0.5

Pump speed r/min 200 200 200

Each cylinder's injection qty mm3/st. 13.4 12.4 14.4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 10.9+-0. 5

Pump speed r/min 100 100 100

Each cylinder's injection qty mm3/st. 74 74 102

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: RAL
----------
K=3 RAL=10.9+-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=30deg+-5deg b=12deg+-5deg c=32deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=53deg+-5deg

Information:

START BY:a. remove valve covers
Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzles turns in the body.
1. Loosen the fuel injection line nut at the nozzle end with tool (A) and a 5P328 crowfoot wrench (7/8").2. Loosen the fuel line nut at the fuel injection line adapter with tool (B). Remove inner fuel injection lines (1). Install caps and plugs on all fuel line openings to keep dirt out of the fuel system. If necessary, use tooling (D) to turn the engine so the valves do not make contact with the pistons when the valves are opened with tool (C) to remove the push rods.3. Put compression on the valve springs with tool (C), and remove push rods (2). Put identification marks on the push rods as to their location in the engine.4. Push the push rod end of the rocker arms down. 5. Remove the intake valve lifter with tooling (E) as follows:a. Install 5P2685 Nut (3) and 5P6601 Collet (4) on 5P2408 Outer Handle Assembly (5).b. Install 5P6599 Inner Handle Assembly (6) in 5P2408 Outer Handle Assembly (5). c. Install tooling (E) in the intake valve lifter. Hold the 5P2408 Outer Handle Assembly, and tighten the 5P6599 Inner Handle Assembly until the 5P6601 Collet is tight against the inside of the intake valve lifter. d. Remove intake valve lifters (7) from the cylinder block with tooling (E). Put identification marks on the lifters as to their location in the engine. 6. Remove the exhaust valve lifters with tooling (E) as follows:a. Install 5P2685 Nut (3) and 5P6601 Collet (4) on 5P2408 Outer Handle Assembly (5). The opening in the cylinder head assembly for the intake valve lifter is larger than the opening in the exhaust valve lifter side. The tooling and each valve lifter must be installed and removed from the intake valve lifter side.b. Install the outer handle assembly in the intake valve lifter side of the cylinder head assembly. Slide the flat area of 5P2408 Outer Handle Assembly (5) through the head casting, and install the 5P6601 Collet in the exhaust valve lifters. c. Install 5P6599 Inner Handle Assembly (6) in 5P2408 Outer Handle Assembly (5). Hold the 5P2408 Handle Assembly, and tighten the 5P6599 Handle Assembly until the 5P6601 Collet is tight against the inside of the exhaust valve lifter.d. Pull the exhaust valve lifter up until the spring on the exhaust valve lifter is free from the cylinder block.e. Remove the 5P6599 Inner Handle Assembly. Slide the 5P2408 Outer Handle Assembly through the head casting, and remove it from the intake valve lifter side of the cylinder head. f. Use a magnet, and remove exhaust valve lifters (8) from the intake valve lifter side of the cylinder head assembly. Put identification marks on the lifters as to their location in the engine.7. Remove the guide springs from the lifters.Install Valve Lifters
Steps 1 and 2