Information injection-pump assembly
BOSCH
9 400 614 174
9400614174
ZEXEL
101452-0000
1014520000
ISUZU
8944593940
8944593940
Rating:
Service parts 101452-0000 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.2(135)
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 614 174
9400614174
ZEXEL
101452-0000
1014520000
ISUZU
8944593940
8944593940
Zexel num
Bosch num
Firm num
Name
101452-0000
9 400 614 174
8944593940 ISUZU
INJECTION-PUMP ASSEMBLY
4FE1 * K
4FE1 * K
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
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
1.95
1.9
2
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
9
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
34.8
33.8
35.8
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
8
6.5
9.5
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
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
C
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
55
55
65
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)Set idle sub-spring
(4)Main spring setting
(5)Rack difference from N = N1
----------
K=11 N1=1400r/min
----------
----------
K=11 N1=1400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=24deg+-5deg b=113deg+5deg
----------
----------
a=24deg+-5deg b=113deg+5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=27mm
----------
a=7.5deg+-5deg b=53deg+-5deg
----------
aa=27mm
----------
a=7.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(50deg)
----------
aa=14deg
----------
a=(50deg)
Information:
Removal Procedure for the Fuel Injection Pump
Table 1
Required Tools
Tool Part Number and Part Description Qty
A 267-2647 Stop Plug 1
B 9S-4180 Plug 1
Remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".Note: Cleanliness is a critical factor. Before you begin the removal procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
Illustration 11 g01352511
Remove tube assembly (1), tube assembly (3), and tube assembly (4) .
Disconnect tube assembly (5) and tube assembly (6). Remove bolts (2) .
Remove Tooling (B) and install Tooling (A) .
Illustration 12 g01352571
Disconnect harness assemblies (8). Remove nuts (9) and the support assembly.
Remove bolts (10). Slide fuel injection pump (11) out of the front housing and disconnect hose assembly (7). Remove fuel injection pump (11) by pulling straight out of the front housing.Installation Procedure for the Fuel Injection Pump
Table 2
Required Tools
Tool Part Number and Part Description Qty
A 267-2647 Stop Plug 1
B 9S-4180 Plug 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
Illustration 13 g01352571
Note: Ensure that Tooling (A) is installed prior to installation of the fuel injection pump.
Align fuel injection pump (11) in the correct orientation relative to the front housing. Connect hose assembly (7) .
Install fuel injection pump (11). Move fuel injection pump (11) straight into the front housing in order to properly engage the gear. Install bolts (10) .
Install the support assembly and nuts (9). Connect harness assemblies (8) .
Illustration 14 g01352511
Remove Tooling (A) and install Tooling (B). Tighten Tooling (B) to a torque of 4.5 0.5 N m (40.0 4.0 lb in).
Install bolts (2). Connect tube assembly (6) and tube assembly (5)
Table 1
Required Tools
Tool Part Number and Part Description Qty
A 267-2647 Stop Plug 1
B 9S-4180 Plug 1
Remove the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".Note: Cleanliness is a critical factor. Before you begin the removal procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
Illustration 11 g01352511
Remove tube assembly (1), tube assembly (3), and tube assembly (4) .
Disconnect tube assembly (5) and tube assembly (6). Remove bolts (2) .
Remove Tooling (B) and install Tooling (A) .
Illustration 12 g01352571
Disconnect harness assemblies (8). Remove nuts (9) and the support assembly.
Remove bolts (10). Slide fuel injection pump (11) out of the front housing and disconnect hose assembly (7). Remove fuel injection pump (11) by pulling straight out of the front housing.Installation Procedure for the Fuel Injection Pump
Table 2
Required Tools
Tool Part Number and Part Description Qty
A 267-2647 Stop Plug 1
B 9S-4180 Plug 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the No. 1 cylinder is at the top center compression stroke. Refer to Testing and Adjusting, "Finding Top Center Position for No. 1 Piston".
Illustration 13 g01352571
Note: Ensure that Tooling (A) is installed prior to installation of the fuel injection pump.
Align fuel injection pump (11) in the correct orientation relative to the front housing. Connect hose assembly (7) .
Install fuel injection pump (11). Move fuel injection pump (11) straight into the front housing in order to properly engage the gear. Install bolts (10) .
Install the support assembly and nuts (9). Connect harness assemblies (8) .
Illustration 14 g01352511
Remove Tooling (A) and install Tooling (B). Tighten Tooling (B) to a torque of 4.5 0.5 N m (40.0 4.0 lb in).
Install bolts (2). Connect tube assembly (6) and tube assembly (5)
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Group cross 101452-0000 ZEXEL
Isuzu
101452-0000
9 400 614 174
8944593940
INJECTION-PUMP ASSEMBLY
4FE1
4FE1