101402-4202 ZEXEL 9 400 613 899 BOSCH INJECTION-PUMP ASSEMBLY 9400613899 1014024202 8970486852

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 899 9400613899

ZEXEL 101402-4202 1014024202

ISUZU 8970486852 8970486852

Service parts 101402-4202 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8873

3. GOVERNOR 105419-0860

4. SUPPLY PUMP 105220-4932

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156637-1521

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6541

11. Nozzle and Holder 8-97013-319-1

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

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105015-4190

15. NOZZLE SET

Include in #1:

101402-4202 as INJECTION-PUMP ASSEMBLY

107691-3562 as _

Cross reference number

BOSCH 9 400 613 899 9400613899

ZEXEL 101402-4202 1014024202

ISUZU 8970486852 8970486852

Zexel num

Bosch num

Firm num

Name

101402-4202
101402-4680

9 400 613 899

8970486852 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1-T * K 14BC 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

Overflow valve 131424-4920

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.4 3.35 3.45

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 9.7

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 76.9 75.8 78

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.6+-0.5

Pump speed r/min 475 475 475

Average injection quantity mm3/st. 8.8 7.4 10.2

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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

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 (4)Rack difference between N = N1 and N = N2
----------
K=5 N1=1150r/min N2=800r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop D:Dead point
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a=(20deg)+-5deg b=(16deg)+-5deg c=(18deg)+-5deg d=13deg+-3deg

Stop lever angle

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

----------
a=6deg+-5deg b=46deg+-5deg

0000001501 LEVER

1. Variable lever adjustment (1)Fix lever B in the idle position using the bolts C and D. (2)Temporarily fix lever A in center of long hole. (3)Set the dead point position temporarily and measure the lever angle. (4)After idle adjustment, loosen the full side stopper bolt D. (5)Move lever A in full speed direction. (6)Fix the bolt D at the full speed position. (7)Fix lever A using bolt E. (8)(G) Lock using bolt. (9)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
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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=18deg
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a=(90deg)