101401-4210 ZEXEL 9 400 613 684 BOSCH INJECTION-PUMP ASSEMBLY 9400613684 1014014210 8970440061

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 684 9400613684

ZEXEL 101401-4210 1014014210

ISUZU 8970440061 8970440061

Include in #1:

108622-3584 as _

Cross reference number

BOSCH 9 400 613 684 9400613684

ZEXEL 101401-4210 1014014210

ISUZU 8970440061 8970440061

Zexel num

Bosch num

Firm num

Name

101401-4210

9 400 613 684

8970440061 ISUZU

INJECTION-PUMP ASSEMBLY
4BD1 * 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 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 10.8

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 63.1 61.5 64.7

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(10.8)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 63.1 62.1 64.1

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. 57.2 54 60.4

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. 66.5 63.3 69.7

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. 45.7 42.5 48.9

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. 44.7 40.7 48.7

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 1250

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1350

Advance angle deg. 1.1

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 1.6

Timer adjustment_04

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=47
----------

Speed control lever angle

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

----------
a=30deg+-5deg b=41deg+-3deg

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)