101401-4201 ZEXEL 9 400 613 683 BOSCH INJECTION-PUMP ASSEMBLY 9400613683 1014014201 8970432591

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 683 9400613683

ZEXEL 101401-4201 1014014201

ISUZU 8970432591 8970432591

Service parts 101401-4201 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8590

3. GOVERNOR 105931-5771

4. SUPPLY PUMP 105210-6130

5. AUTOM. ADVANCE MECHANIS 105671-0061

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4321

11. Nozzle and Holder 8-94447-686-1

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

13. NOZZLE-HOLDER 105048-5011

14. NOZZLE 105017-1660

15. NOZZLE SET

Include in #1:

101401-4201 as INJECTION-PUMP ASSEMBLY

108822-3228 as _

Cross reference number

BOSCH 9 400 613 683 9400613683

ZEXEL 101401-4201 1014014201

ISUZU 8970432591 8970432591

Zexel num

Bosch num

Firm num

Name

101401-4201

9 400 613 683

8970432591 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 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
After adjusting injection quantity. 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 11.4

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 62.4 60.8 64

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 275 275 275

Average injection quantity mm3/st. 9.4 8.1 10.7

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(11.4)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 62.4 61.4 63.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(11.4)

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 70.3 67.1 73.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 46.9 43.7 50.1

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 90 90 98

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1100--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1050

Advance angle deg. 0.3

Timer adjustment_03

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)At delivery (at R = A, N = N1)
----------
T1=D41 N1=100r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Set the idle side stopper bolt at rack position = aa (at delivery).
----------
aa=11.4mm
----------
a=(2.5deg) b=43deg+-3deg c=2.5deg+-5deg

Stop lever angle

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

----------
a=45deg+-5deg b=29deg+-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=15deg
----------
a=(90deg)