101491-0354 ZEXEL 9 400 614 279 BOSCH INJECTION-PUMP ASSEMBLY 9400614279 1014910354 8944644695

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 279 9400614279

ZEXEL 101491-0354 1014910354

ISUZU 8944644695 8944644695

Service parts 101491-0354 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8490

3. GOVERNOR 105931-4272

4. SUPPLY PUMP 105210-4610

5. AUTOM. ADVANCE MECHANIS 105622-1220

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:

101402-3290 as _

101491-0354 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 614 279 9400614279

ZEXEL 101491-0354 1014910354

ISUZU 8944644695 8944644695

Zexel num

Bosch num

Firm num

Name

101491-0354

9 400 614 279

8944644695 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 10.5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 56 54.4 57.6

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.7+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9.5 8 11

Max. variation between cylinders % 0 -10 10

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(10.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 56 55 57

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.05

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 55 51.8 58.2

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. 42.1 38.9 45.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 41.7 37.7 45.7

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 56 51 61

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 (3)The torque cam setting and high idle must be set when speed is increasing from low to high (because of hysterisis).
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T1=A73
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
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aa=50mm
----------
a=29deg+-5deg b=41deg+-3deg

0000001501 MICRO SWITCH

(A) Cam fixing bolt (B) Screw B (C) Cam (select) (D) Microswitch fixing bolt (E) Microswitch (F) Adjusting direction (G) Idle adjusting bolt (H) Full speed adjusting bolt (T) Distance Adjustment of the micro-switch 1. Adjustment specifications (1)Full side switch ON position When a thickness gauge is inserted between the speed lever and the full speed adjusting bolt and the speed lever is moved from the idle side to the full side. Confirm no continuity using a thickness gauge t = 0.3. Confirm no continuity using a thickness gauge t = 0.1. (2)Idle side switch ON. When a thickness gauge is inserted between the speed lever and the idle adjusting bolt and the speed lever is moved from the full side to the idle side. Confirm no continuity using a thickness gauge t = 1.1. Confirm no continuity using a thickness gauge t = 0.5. 2. Procedures for adjustment (1)Standard position for Cam (159226-8100), stamping mark M, is explained in above illustration. (2)Fix the microswitch body in the position shown in the figure above. (The microswitch is free.) (3)Full side adjustment Adjust using screw B to satisfy the adjustment specifications (1) above. (4)Idle side confirmation Move the speed lever from the full side to the idle side and confirm the above adjustment specification (2). (5)When the idle side is not as specified, replace the cam (stamping S or L) and repeat adjustment from procedure 2.(2) above.
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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=16deg
----------
a=(100deg)