101401-0592 ZEXEL 9 400 610 389 BOSCH INJECTION-PUMP ASSEMBLY 9400610389 1014010592 8941787192

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 389 9400610389

ZEXEL 101401-0592 1014010592

ISUZU 8941787192 8941787192

Service parts 101401-0592 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8450

3. GOVERNOR 105931-2104

4. SUPPLY PUMP 105210-6130

5. AUTOM. ADVANCE MECHANIS 105670-0181

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder 5-15300-089-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101401-0592 as INJECTION-PUMP ASSEMBLY

107491-3051 as _

Cross reference number

BOSCH 9 400 610 389 9400610389

ZEXEL 101401-0592 1014010592

ISUZU 8941787192 8941787192

Zexel num

Bosch num

Firm num

Name

101401-0592

9 400 610 389

8941787192 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1 K 14BC INJECTION PUMP ASSY PE4A,5A, 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 opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.6 3.55 3.65

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 -

Rack position 11.2

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 66.7 65.1 68.3

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.2)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 66.7 65.7 67.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.4

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 63.3 60.1 66.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.1

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 70.7 67.5 73.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.25

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 49.6 46.4 52.8

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 49 45 53

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 95 95 103

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1050+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Torque cam set point
----------
T1=A47
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=5.5deg+-5deg b=41deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=45deg+-5deg b=40deg+-5deg

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=13deg
----------
a=(100deg)