101491-0293 ZEXEL 9 400 614 276 BOSCH INJECTION-PUMP ASSEMBLY 9400614276 1014910293 8941788184

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 276 9400614276

ZEXEL 101491-0293 1014910293

ISUZU 8941788184 8941788184

Service parts 101491-0293 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8510

3. GOVERNOR 105931-2135

4. SUPPLY PUMP 105210-6130

5. AUTOM. ADVANCE MECHANIS 105622-1590

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6391

11. Nozzle and Holder 8-94151-865-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-6060

15. NOZZLE SET

Include in #1:

101491-0293 as INJECTION-PUMP ASSEMBLY

101492-3310 as _

Cross reference number

BOSCH 9 400 614 276 9400614276

ZEXEL 101491-0293 1014910293

ISUZU 8941788184 8941788184

Zexel num

Bosch num

Firm num

Name

101491-0293

9 400 614 276

8941788184 ISUZU

INJECTION-PUMP ASSEMBLY
4BC2 * 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

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 10.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 49.2 47.6 50.8

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 -

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(10.2)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 49.2 48.2 50.2

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. 46.5 43.3 49.7

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. 39.8 36.6 43

Fixing the lever *

Injection quantity adjustment_06

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 1300--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1250

Advance angle deg. 0.6

Timer adjustment_03

Pump speed r/min 1900

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=A49
----------

Speed control lever angle

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

----------
a=5.5deg+-5deg b=37deg+-3deg

Stop lever angle

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

----------
a=45deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 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)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=1100r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(10.2)mm Rb=(R1-0.4)mm Pa=4+-2.7kPa(30+-20mmHg) Pb=22kPa(165mmHg) Q1=49.2+-1cm3/1000st Q2=41.1+-1cm3/1000st

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=16deg
----------
a=(100deg)