101402-8231 ZEXEL 9 400 613 494 BOSCH INJECTION-PUMP ASSEMBLY 9400613494 1014028231 8973645841


101402-8231 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 494 9400613494
ZEXEL 101402-8231 1014028231
ISUZU 8973645841 8973645841

Service parts 101402-8231 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101040-4150
3. GOVERNOR 105411-2790
4. SUPPLY PUMP 105220-7570
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:

101402-8231 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 494 9400613494
ZEXEL 101402-8231 1014028231
ISUZU 8973645841 8973645841


Zexel num
Bosch num
Firm num
Name
101402-8231 
9 400 613 494 
8973645841  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   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
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   10.9
Pump speed r/min   1200 1200 1200
Average injection quantity mm3/st.   104 102.9 105.1
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Boost pressure kPa   82.6 82.6
Boost pressure mmHg   620 620
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.7+-0.5
Pump speed r/min   650 650 650
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   11.1++
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   R1-0.95
Boost pressure kPa   23.3 19.3 27.3
Boost pressure mmHg   175 145 205
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R1(10.9)
Boost pressure kPa   69.3 62.6 76
Boost pressure mmHg   520 470 570

Test data Ex:

Governor adjustment

Test data 101402-8231
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Rack difference between N = N1 and N = N2 (5)Boost compensator stroke: BCL (6)Set idle sub-spring (7)Main spring setting
----------
K=13 N1=1200r/min N2=350r/min BCL=0.95+-0.1mm
----------

Speed control lever angle

Test data 101402-8231
F:Full speed I:Idle S:Stop (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=94mm
----------
a=19deg+-5deg b=11deg+-5deg c=35deg+-3deg

Stop lever angle

Test data 101402-8231
N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)(Seal at delivery.) (3)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=32deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Test data 101402-8231
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 101402-8231
(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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