Information injection-pump assembly
BOSCH
9 400 614 268
9400614268
ZEXEL
101491-0083
1014910083
ISUZU
5156013674
5156013674
Rating:
Service parts 101491-0083 INJECTION-PUMP ASSEMBLY:
1.
_
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
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
4BC2 K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
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.
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
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
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
----------
----------
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
----------
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)
----------
aa=15deg
----------
a=(100deg)
Information:
Termination Date
January 31, 1993Problem
The fuel injection pumps used on certain Remanufactured 1160 and 3208 Engines need to be inspected for gummy deposits.
Affected Product
Model & Identification Number
1160 (57V1-34325)
3208 (9WC1-730; 5CD1-5868; 62W1-68596; 93Z1-8374)
Remanufactured Fuel Pump Part Numbers
0R07660R09030R23840R23860R09020R23740R23850R2877 The above list of remanufactured pumps are affected only if they are stamped with a date code of 12/91 (UMDU) or earlier.
Parts Needed
Not Applicable
Action Required
Before installing or delivering any of the affected product, perform the following steps to ensure the internal fuel injection pump components are not stuck due to fuel pump gumming:
1. Remove the top cover of the fuel injection pump and check to ensure that all sleeves and levers are free and there are no gummy deposits on any of these components.2. If inspection performed in Step 1 indicates everything is clean, install top cover and return to parts stock.3. If inspection reveals components have gummy deposits, remove 12 ounces of fuel from the fuel pump housing and replace it with: - Fuel Injector Cleaner or
- Carburetor/Choke Cleaner
4. Allow the components to soak in cleaning solution for 45 minutes, then rotate the engine crankshaft to rotate the fuel injection pump (on pumps only, rotate the fuel pump camshaft). This will ensure the components have the gummy deposits removed. If the engine or fuel pump will be used immediately, install the cover on the fuel injection pump, and install or deliver the engine or pump.5. If the engine or fuel pump will be returned to stock, DO NOT leave the fuel injection pump full of cleaning solution because it may not contain any rust inhibitors. Remove the cleaning solution, fill the fuel injector pump with clean diesel fuel, and install the cover on the pump.Service Claim Allowances
It is a .5-hr. job to inspect the pump. An additional .5-hr. may be claimed if cleaning is required.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
January 31, 1993Problem
The fuel injection pumps used on certain Remanufactured 1160 and 3208 Engines need to be inspected for gummy deposits.
Affected Product
Model & Identification Number
1160 (57V1-34325)
3208 (9WC1-730; 5CD1-5868; 62W1-68596; 93Z1-8374)
Remanufactured Fuel Pump Part Numbers
0R07660R09030R23840R23860R09020R23740R23850R2877 The above list of remanufactured pumps are affected only if they are stamped with a date code of 12/91 (UMDU) or earlier.
Parts Needed
Not Applicable
Action Required
Before installing or delivering any of the affected product, perform the following steps to ensure the internal fuel injection pump components are not stuck due to fuel pump gumming:
1. Remove the top cover of the fuel injection pump and check to ensure that all sleeves and levers are free and there are no gummy deposits on any of these components.2. If inspection performed in Step 1 indicates everything is clean, install top cover and return to parts stock.3. If inspection reveals components have gummy deposits, remove 12 ounces of fuel from the fuel pump housing and replace it with: - Fuel Injector Cleaner or
- Carburetor/Choke Cleaner
4. Allow the components to soak in cleaning solution for 45 minutes, then rotate the engine crankshaft to rotate the fuel injection pump (on pumps only, rotate the fuel pump camshaft). This will ensure the components have the gummy deposits removed. If the engine or fuel pump will be used immediately, install the cover on the fuel injection pump, and install or deliver the engine or pump.5. If the engine or fuel pump will be returned to stock, DO NOT leave the fuel injection pump full of cleaning solution because it may not contain any rust inhibitors. Remove the cleaning solution, fill the fuel injector pump with clean diesel fuel, and install the cover on the pump.Service Claim Allowances
It is a .5-hr. job to inspect the pump. An additional .5-hr. may be claimed if cleaning is required.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Have questions with 101491-0083?
Group cross 101491-0083 ZEXEL
Isuzu
101491-0083
9 400 614 268
5156013674
INJECTION-PUMP ASSEMBLY
4BC2
4BC2