101481-0180 ZEXEL 9 400 614 203 BOSCH INJECTION-PUMP ASSEMBLY 9400614203 1014810180 8970892591

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 203 9400614203

ZEXEL 101481-0180 1014810180

ISUZU 8970892591 8970892591

Service parts 101481-0180 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101048-8141

3. GOVERNOR 105931-9871

4. SUPPLY PUMP 105210-4630

5. AUTOM. ADVANCE MECHANIS 105622-1830

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-2870

11. Nozzle and Holder 8-97025-466-0

12. Open Pre:MPa(Kqf/cm2) 13.2{135}

13. NOZZLE-HOLDER 105071-1380

14. NOZZLE 105000-1871

15. NOZZLE SET

Include in #1:

101481-0180 as INJECTION-PUMP ASSEMBLY

104302-2031 as _

Cross reference number

BOSCH 9 400 614 203 9400614203

ZEXEL 101481-0180 1014810180

ISUZU 8970892591 8970892591

Zexel num

Bosch num

Firm num

Name

101481-0180
101481-0200

9 400 614 203

8970892591 ISUZU

INJECTION-PUMP ASSEMBLY
4BD2 * 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 2.8 2.75 2.85

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 12

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 79.5 77.9 81.1

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 400 400 400

Average injection quantity mm3/st. 13 11.7 14.3

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(12)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 79.5 78.5 80.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 1375 1375 1375

Average injection quantity mm3/st. 81 77 85

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 66 62 70

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 93 93 109

Fixing the lever *

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 2.5 2 3

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.
----------
T=J13
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=7.5deg+-5deg b=33deg+-3deg

Stop lever angle

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

----------
a=45deg+-5deg b=29deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
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N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
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Ra=R1(12)mm Rb=R1-0.25mm Pa=74.6+-2.7kPa(560+-20mmHg) Pb=61.6+-0.7kPa(462+-5mmHg) Q1=79.5+-1cm3/1000st Q2=(74)+-2cm3/1000st

0000001601 FICD

Nut A (B) Screw Negative pressure port C 1. FICD adjustment (1)Loosen nut A and screw in screw B. (2)Apply negative pressure P1 to C, turn screw B slowly and tighten nut A at N1 and R1. (3)Nut A tightening torque T1 (4)Apply negative pressure P2 to C several times and confirm that the FICD operates normally.
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P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) N1=450r/min R1=9.3+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L1=3+1mm

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=10deg
----------
a=(100deg)