101402-8030 ZEXEL 9 400 612 605 BOSCH INJECTION-PUMP ASSEMBLY 9400612605 1014028030 8973195040

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 605 9400612605

ZEXEL 101402-8030 1014028030

ISUZU 8973195040 8973195040

Service parts 101402-8030 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8390

3. GOVERNOR 105411-2410

4. SUPPLY PUMP 105220-7140

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-9620

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5250

11. Nozzle and Holder 8-97288-122-0

12. Open Pre:MPa(Kqf/cm2) 22.1{225}

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105025-3540

15. NOZZLE SET

Include in #1:

101402-8030 as INJECTION-PUMP ASSEMBLY

106671-4684 as _

Cross reference number

BOSCH 9 400 612 605 9400612605

ZEXEL 101402-8030 1014028030

ISUZU 8973195040 8973195040

Zexel num

Bosch num

Firm num

Name

101402-8030

9 400 612 605

8973195040 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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 3.45 3.4 3.5

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 1450 1450 1450

Average injection quantity mm3/st. 106 104.4 107.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 173 173

Boost pressure mmHg 1300 1300

Injection quantity adjustment_02

Adjusting point B

Rack position 7.3+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 14 12.7 15.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position 7.65

Boost pressure kPa 20 16 24

Boost pressure mmHg 150 120 180

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 9.15

Boost pressure kPa 160 153.3 166.7

Boost pressure mmHg 1200 1150 1250

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)Boost compensator stroke (4)Set idle sub-spring (5)Main spring setting
----------
K=17
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa
----------
aa=70mm
----------
a=22deg+-5deg b=32deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb (stamp at delivery) (2)Normal (3)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=40mm
----------
a=32deg+-5deg b=(55deg)

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=17deg
----------
a=(90deg)