101401-0992 ZEXEL 9 400 613 594 BOSCH INJECTION-PUMP ASSEMBLY 9400613594 1014010992 8970103244

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 594 9400613594

ZEXEL 101401-0992 1014010992

ISUZU 8970103244 8970103244

Service parts 101401-0992 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8800

3. GOVERNOR 105931-6741

4. SUPPLY PUMP 105210-4860

5. AUTOM. ADVANCE MECHANIS 105671-0140

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4724

11. Nozzle and Holder 8-94479-578-3

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3352

14. NOZZLE

105017-0640

15. NOZZLE SET

Include in #1:

101401-0992 as INJECTION-PUMP ASSEMBLY

106873-3342 as _

Cross reference number

BOSCH 9 400 613 594 9400613594

ZEXEL 101401-0992 1014010992

ISUZU 8970103244 8970103244

Zexel num

Bosch num

Firm num

Name

101401-0992

9 400 613 594

8970103244 ISUZU

INJECTION-PUMP ASSEMBLY
4BG1 * 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 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 3.6 3.55 3.65

Rack position
Point A R=A

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 11.3

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 69.6 68 71.2

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 350 350 350

Average injection quantity mm3/st. 9.8 8.5 11.1

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(11.3)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 69.6 68.6 70.6

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1525 1525 1525

Average injection quantity mm3/st. 82.1 78.9 85.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(11.3)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 53.1 49.9 56.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 86 78 94

Fixing the lever *

Timer adjustment

Pump speed r/min 1370--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1320

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 5 4.5 5.5

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.
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T1=D65
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=4.5deg+-5deg b=(31.5deg)+-3deg

0000001501 FICD

Negative pressure port A (B) Screw 1. FICD adjustment (1)Set the clearance between the actuator and the speed lever at L1. (2)Fully screw in screw B. (3)Apply P1 to negative pressure port A and gradually tighten screw B. (4)Fix the screw (B) at pump speed N1 and rack position R1. (Tightening torque = T1) (5)Apply P2 to negative pressure port A and confirm that the FICD operates normally.
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L1=(3)mm P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) N1=600r/min R1=9.2+-0.1mm
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