101491-0083 ZEXEL 9 400 614 268 BOSCH INJECTION-PUMP ASSEMBLY 9400614268 1014910083 5156013674

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 268 9400614268

ZEXEL 101491-0083 1014910083

ISUZU 5156013674 5156013674

Service parts 101491-0083 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8500

3. GOVERNOR 105931-0913

4. SUPPLY PUMP 105220-7450

5. AUTOM. ADVANCE MECHANIS 105622-0861

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101491-0083 as INJECTION-PUMP ASSEMBLY

106672-4361 as _

Cross reference number

BOSCH 9 400 614 268 9400614268

ZEXEL 101491-0083 1014910083

ISUZU 5156013674 5156013674

Zexel num

Bosch num

Firm num

Name

101491-0083

9 400 614 268

5156013674 ISUZU

INJECTION-PUMP ASSEMBLY
4BC2 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

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 3.4 3.35 3.45

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 10.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 53 51.4 54.6

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 9.9+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9.5 8 11

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.4)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 53 52 54

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 51.8 48.6 55

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.1

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 42.2 39 45.4

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.7

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 42 38 46

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 57.5 52.5 62.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1650--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 0.6

Timer adjustment_03

Pump speed r/min 1800

Advance angle deg. 3 2.5 3.5

Timer adjustment_04

Pump speed r/min 1900

Advance angle deg. 4.5 4 5

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 5 5 5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=55
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)Pump speed aa and rack position bb (lever angle when engine side microswitch ON)
----------
aa=1400r/min bb=7.2mm
----------
a=5.5deg+-5deg b=40deg+-3deg c=22deg+-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=15deg
----------
a=(100deg)