101402-8080 ZEXEL 9 400 613 986 BOSCH INJECTION-PUMP ASSEMBLY 9400613986 1014028080 8973258420

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 986 9400613986

ZEXEL 101402-8080 1014028080

ISUZU 8973258420 8973258420

Service parts 101402-8080 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-4070

3. GOVERNOR 105411-2510

4. SUPPLY PUMP 105220-7560

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)

13. NOZZLE-HOLDER 105030-4750

14. NOZZLE 105025-3030

15. NOZZLE SET

Include in #1:

101402-8080 as INJECTION-PUMP ASSEMBLY

106684-4490 as _

Cross reference number

BOSCH 9 400 613 986 9400613986

ZEXEL 101402-8080 1014028080

ISUZU 8973258420 8973258420

Zexel num

Bosch num

Firm num

Name

101402-8080

9 400 613 986

8973258420 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 255 255 255

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)Rack difference between N = N1 and N = N2 (6)Main spring setting (7)Set idle sub-spring
----------
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 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

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)
----------
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)-
----------
aa=7deg
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a=(100deg)