101402-7815 ZEXEL 9 400 612 780 BOSCH INJECTION-PUMP ASSEMBLY 9400612780 1014027815 8972541185

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 780 9400612780

ZEXEL 101402-7815 1014027815

ISUZU 8972541185 8972541185

Service parts 101402-7815 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-4070

3. GOVERNOR 105411-2293

4. SUPPLY PUMP 105220-6670

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-4120

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5120

11. Nozzle and Holder 1-15300-394-0

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

13. NOZZLE-HOLDER 105030-4750

14. NOZZLE 105025-3030

15. NOZZLE SET

Include in #1:

101402-7815 as INJECTION-PUMP ASSEMBLY

106679-4151 as _

Cross reference number

BOSCH 9 400 612 780 9400612780

ZEXEL 101402-7815 1014027815

ISUZU 8972541185 8972541185

Zexel num

Bosch num

Firm num

Name

101402-7815

9 400 612 780

8972541185 ISUZU

INJECTION-PUMP ASSEMBLY
4BG1-T K 14BD INJECTION PUMP ASSY PE4AD 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 134424-4120

Overflow valve opening pressure kPa 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 4.2 4.15 4.25

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 10

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 85.5 84.4 86.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 93.3 93.3

Boost pressure mmHg 700 700

Injection quantity adjustment_02

Adjusting point -

Rack position 7.7+-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 *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Injection quantity adjustment_03

Adjusting point E

Rack position 10.9++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 75 85

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position 8.7

Boost pressure kPa 40 36 44

Boost pressure mmHg 300 270 330

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position 9

Boost pressure kPa 80 73.3 86.7

Boost pressure mmHg 600 550 650

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 (4)Boost compensator stroke: BCL (5)Main spring setting (6)Set idle sub-spring (7)Rack difference between N = N1 and N = N2
----------
K=9 BCL=0.3+-0.1mm N1=1100r/min N2=650r/min
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Speed control lever angle

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

----------
a=3deg+-5deg b=20deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)(Seal at delivery.) (3)Stopper bolt setting (4)Stopper bolt setting (5)The stop lever does not have to return to the stop position (but set screw at rack position = cc). (6)No return spring
----------
aa=0r/min bb=1-0.5mm cc=1-0.5mm
----------
a=10deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads. (B): Specified torque (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
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T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
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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)-
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aa=7deg
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a=(100deg)