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


101481-0180 INJECTION-PUMP ASSEMBLY
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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

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

Test data 101481-0180
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

Test data 101481-0180
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

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

Stop lever angle

Test data 101481-0180
N:Pump normal S:Stop the pump.
----------

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

0000001501 ACS

Test data 101481-0180
(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.
----------
N1=950r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
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

Test data 101481-0180
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.
----------
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

Test data 101481-0180
(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)




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