101481-0232 ZEXEL 9 400 610 514 BOSCH INJECTION-PUMP ASSEMBLY 9400610514 1014810232 8971320502

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 514 9400610514

ZEXEL 101481-0232 1014810232

ISUZU 8971320502 8971320502

Service parts 101481-0232 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101048-8180

3. GOVERNOR 105932-1520

4. SUPPLY PUMP 105210-6111

5. AUTOM. ADVANCE MECHANIS 105622-1861

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-2911

11. Nozzle and Holder 8-97042-322-1

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

13. NOZZLE-HOLDER 105071-1380

14. NOZZLE 105000-2280

15. NOZZLE SET

Include in #1:

101481-0232 as INJECTION-PUMP ASSEMBLY

104303-2070 as _

Cross reference number

BOSCH 9 400 610 514 9400610514

ZEXEL 101481-0232 1014810232

ISUZU 8971320502 8971320502

Zexel num

Bosch num

Firm num

Name

101481-0232
101481-0250

9 400 610 514

8971320502 ISUZU

INJECTION-PUMP ASSEMBLY
4BD2 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 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 11.9

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 77 75.4 78.6

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(11.9)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 77 76 78

Basic *

Fixing the lever *

Boost pressure kPa 62.7 62.7

Boost pressure mmHg 470 470

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1375 1375 1375

Average injection quantity mm3/st. 79 75 83

Fixing the lever *

Boost pressure kPa 62.7 62.7

Boost pressure mmHg 470 470

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-0.35 )

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 63 59 67

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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 *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 950 950 950

Rack position R1-0.7

Boost pressure kPa 8 6.7 9.3

Boost pressure mmHg 60 50 70

Boost compensator adjustment_02

Pump speed r/min 950 950 950

Rack position R1(11.9)

Boost pressure kPa 49.3 49.3 49.3

Boost pressure mmHg 370 370 370

Timer adjustment

Pump speed r/min 600--

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. (3)Boost compensator stroke: BCL
----------
T1=J45 BCL=0.7+-0.1mm
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Speed control lever angle

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

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

Stop lever angle

N:Pump normal S:Stop the pump.
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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=24+-0.5mm h1=0.15mm
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Ra=R1(11.9)mm Rb=R1-0.25mm Pa=74.6+-2.7kPa(560+-20mmHg) Pb=61.6+-0.7kPa(462+-5mmHg) Q1=77+-1cm3/1000st Q2=(72)+-2cm3/1000st

0000001601 ACS

(A) Aneroid compensator (B) Set screw (C) Boost pressure inlet (D) Rack positioning screw (E): Aneroid compensator main body (F) Boost compensator spring (G): Aneroid compensator spring (H): Adjusting notch (I) Push rod 1. Instructions for adjusting the boost compensator with the aneroid compensator (1)Select a pushrod to obtain L1 at full boost. (2)Remove the aneroid compensator main body. (3)Adjust the booster compensator stroke by turning the screw at (D. (4)Adjust the beginning of boost compensator operation by turning the notch at (H). (5)Install the aneroid compensator at full boost state. (6)Turn (B)'s set screw so that the distance between the snapring and the body is L2. (7)Screw in the aneroid compensator main body and adjust the point where it comes into play.
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L1=24+-0.5mm L2=1.5+-0.5mm
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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)-
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aa=11deg
----------
a=(100deg)