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


101402-8080 INJECTION-PUMP ASSEMBLY
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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

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

Test data 101402-8080
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
----------

Speed control lever angle

Test data 101402-8080
F:Full speed I:Idle (1)Stopper bolt setting
----------

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

Stop lever angle

Test data 101402-8080
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 101402-8080
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)
----------

Timing setting

Test data 101402-8080
(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
----------
a=(100deg)




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