101492-0640 ZEXEL 9 400 614 403 BOSCH INJECTION-PUMP ASSEMBLY 9400614403 1014920640 8970491920

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 403 9400614403

ZEXEL 101492-0640 1014920640

ISUZU 8970491920 8970491920

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Buy INJECTION-PUMP ASSEMBLY 101492-0640 zexel genuine, new aftermarket engine parts with delivery

Service parts 101492-0640 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9800

3. GOVERNOR 105400-7550

4. SUPPLY PUMP 105220-5850

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156637-0620

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4065

11. Nozzle and Holder 8-94122-262-5

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

13. NOZZLE-HOLDER 105048-3890

14. NOZZLE 105017-1540

15. NOZZLE SET

Include in #1:

101492-0640 as INJECTION-PUMP ASSEMBLY

106682-9460 as _

Cross reference number

BOSCH 9 400 614 403 9400614403

ZEXEL 101492-0640 1014920640

ISUZU 8970491920 8970491920

Zexel num

Bosch num

Firm num

Name

101492-0640

9 400 614 403

8970491920 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1 * K 14BE PE6A 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 131424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 3.3 3.25 3.35

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 11.1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 50.8 49.8 51.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.5+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8.7 6.7 10.7

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Set idle sub-spring (3)Main spring setting
----------
K=15
----------

Speed control lever angle

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

----------
a=31deg+-5deg b=12deg+-5deg c=32deg+-3deg

Stop lever angle

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

----------
a=0deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'V' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=17deg
----------
a=(200deg)

Information:

Start By:a. remove timing gear coverb. remove flywheel housing*c. remove engine oil cooler**d. remove oil filter base***Put the engine in time before the flywheel housing is removed. See the topic, "Finding Top Center Compression Position For No. 1 Piston" in Testing & Adjusting Manual SENR6471.**These operations must be done to install Tool (A) on the engine.
Typical Example1. Fasten the engine on Tool (A). The weight of the engine is 1362 kg (3000 lb).2. Remove the bolts and nuts that hold air cleaner group (1), pipe assembly (3), bracket assembly (4) and lifting plate (5) as a unit to the engine. Fasten a hoist to the unit and remove it from the engine. The weight of the unit is approximately 39 kg (85 lb).3. Remove tube assembly (2) from the engine.
Typical Example4. Install the two bolts to hold the primary fuel filter bracket (6) in place while the engine is turned with Tool (A). 5. Turn the engine to the position shown with Tool (A). Remove rod bearing caps (8) from the ends of the connecting rods. Push the connecting rods away from the crankshaft.6. Remove the bolts and remove main bearing caps (7) from the crankshaft. 7. Remove thrust plates (9) from the center main bearing journal. 8. Fasten a hoist to crankshaft (10) with tooling (B). Remove crankshaft (10) from the engine block. The weight of the crankshaft is 159 kg (350 lb). 9. Use Tool (C) to remove outer gear (2) from the end of the crankshaft.10. Use a hammer and chisel to remove the spacer from the crankshaft. 11. Use Tool (D) to remove the gear alignment dowel from the crankshaft.12. Use Tool (C) to remove inner gear (11) from the end of the crankshaft. If new main bearings are not to be installed, put identification on the old main bearings as to their location in the cylinder block and to which main bearings caps they belong.13. Remove main bearings (13) from the cylinder block and the main bearing caps.Install Crankshaft
1. If the dowel was removed from the flywheel end of the crankshaft, install it in the crankshaft to a maximum dimension of 6.4 mm (.25 in).2. Heat the crankshaft gears to a maximum temperature of 205° C (400° F).3. The centerline of inner gear key must be in alignment with the centerline of the dowel hole within 0.51 mm (.020 in). Install crankshaft inner gear (14) on the crankshaft.4. Install the spacer on the crankshaft.5. Install the dowel in the crankshaft. The dowel must be extended no more than 4.1 0.5 mm (.16 .02 in) from the surface of the crankshaft. The dowel in the crankshaft must be in alignment with the notch in crankshaft gear (15).6. Make sure the "V" mark on the crankshaft gear is toward the outside, and install crankshaft gear (15). 7. Thoroughly clean the cylinder block and main bearing caps.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit