104304-3260 ZEXEL 9 400 616 508 BOSCH INJECTION-PUMP ASSEMBLY 9400616508 1043043260 8941448541

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 508 9400616508

ZEXEL 104304-3260 1043043260

ISUZU 8941448541 8941448541

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Cross reference number

BOSCH 9 400 616 508 9400616508

ZEXEL 104304-3260 1043043260

ISUZU 8941448541 8941448541

Zexel num

Bosch num

Firm num

Name

104304-3260

9 400 616 508

8941448541 ISUZU

INJECTION-PUMP ASSEMBLY
4FA1 * K

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 1-3-4-2

Pre-stroke mm 2.1 2.05 2.15

Rack position
Point A R=A

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 8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 24.6 24.1 25.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.5+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -14 14

Fixing the lever *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point C

Rack position 7.5

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 25 23 27

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Set idle sub-spring (2)Main spring setting (3)Rack difference between N = N1 and N = N2 (4)Rack difference between N = N3 and N = N4
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N1=1100r/min N2=1000r/min N3=1250r/min N4=1000r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=7deg+-3deg b=16deg+-6deg

Stop lever angle

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

----------
a=18deg+-5deg b=(38deg)

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (same as key groove position) (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(50deg)

Information:

Start By:a. remove flywheel
The crankshaft rear seal and wear sleeve must both be removed because they must be replaced as a new set. The new seal set must not be separated.
1. Use a sharp punch and a hammer to put four equally spaced holes in seal (1).2. Install the tip of Tool (A) into the seal, and use the slide hammer to pull it out of the flywheel housing. Change the location of Tool (A) in the seal in order to pull the seal out evenly. 3. Install two 5/8 "-18 NF × 4 in. (102 mm) long bolts (2) to hold the crankshaft rear gear in position.4. Install 5P-7314 Distorter Ring (3) [part of Tooling (B)] in the space where the seal was removed.
Be careful not to damage the crankshaft rear gear.
5. Use 5P-7312 Distorter Ring (4) [part of Tooling (B)] to distort the wear sleeve. Put the end of the distorter in the space where the seal was removed.6. Turn the distorter to cause distortion to the wear sleeve. Move the distorter to another position, and turn the distorter again. Do this procedure until the wear sleeve is loose on the crankshaft.7. Remove the distorter, distorter ring and wear sleeve.Install Crankshaft Rear Seal & Wear Sleeve
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the front seal group for an engine is different from the rear seal group. If a seal group is installed on the wrong end of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
1. Fasten Tooling (A) to the crankshaft rear gear.2. Use 6V-1541 Quick Cure Primer to clean the outside diameter of the crankshaft rear gear and inside diameter of the wear sleeve in seal assembly (1).3. Put 9S-3265 Retaining Compound on the outside diameter of the crankshaft rear gear and the inside diameter of the wear sleeve in seal assembly (1).
Do not separate the lip-type seal from the wear sleeve. The material in the large lip of the seal can be damaged easily. A scratch or rub (not visible) from a finger can damage the seal enough that it cannot be used. Install the sleeve in the seal. Once there is separation of the sleeve and lip-type seal they cannot be used again and must be replaced with a new seal group. Do not use any type of lubrication during installation of the seal group. If any type of lubrication is used in the installation of the seal group, early seal failure can result.
4. Put seal group (1) in position on Tooling (A). Be sure direction arrows on the seal are the same as crankshaft rotation. 5. Put clean engine oil on the face of washer on nut (2) [part of Tooling (B)] that contacts the installer.6. Install Tooling (B) onto Tooling (A), and install nut (2) [part of Tooling (B)] on the threaded shaft of Tooling