101402-7890 ZEXEL 9 400 612 296 BOSCH INJECTION-PUMP ASSEMBLY 9400612296 1014027890 8973000020


101402-7890 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 612 296 9400612296
ZEXEL 101402-7890 1014027890
ISUZU 8973000020 8973000020

Service parts 101402-7890 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-8950
3. GOVERNOR 105411-2390
4. SUPPLY PUMP 105220-6670
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156643-3320
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-5241
11. Nozzle and Holder 1-15300-421-0
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105030-4750
14. NOZZLE 105025-3730
15. NOZZLE SET

Include in #1:

101402-7890 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 296 9400612296
ZEXEL 101402-7890 1014027890
ISUZU 8973000020 8973000020


Zexel num
Bosch num
Firm num
Name
101402-7890 
101402-7891 
9 400 612 296 
8973000020  ISUZU
INJECTION-PUMP ASSEMBLY
4BG1-T * 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
Overflow valve   134424-4120
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
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   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   10.5
Pump speed r/min   1075 1075 1075
Average injection quantity mm3/st.   93.5 92.4 94.6
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Boost pressure kPa   57.3 57.3
Boost pressure mmHg   430 430
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   10.7++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   120 115 125
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   R1-0.5
Boost pressure kPa   24.7 20.7 28.7
Boost pressure mmHg   185 155 215
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R1(9.9)
Boost pressure kPa   44 37.3 50.7
Boost pressure mmHg   330 280 380

Test data Ex:

Governor adjustment

Test data 101402-7890
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 (5)Rack difference between N = N1 and N = N2
----------
K=9 N1=1075r/min N2=500r/min
----------

Speed control lever angle

Test data 101402-7890
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=70mm
----------
a=4deg+-5deg b=20deg+-5deg

Stop lever angle

Test data 101402-7890
N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=32deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Test data 101402-7890
Tamperproofing-equipped boost compensator cover installation procedure (A) After adjusting the boost compensator, tighten the bolts to remove the heads. (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)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

Timing setting

Test data 101402-7890
(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=9deg
----------
a=(100deg)




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