101491-0104 ZEXEL 9 400 614 269 BOSCH INJECTION-PUMP ASSEMBLY 9400614269 1014910104 5156013935


 

Information injection-pump assembly

BOSCH 9 400 614 269 9400614269
ZEXEL 101491-0104 1014910104
ISUZU 5156013935 5156013935
101491-0104 INJECTION-PUMP ASSEMBLY
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Service parts 101491-0104 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101049-8500
3. GOVERNOR 105931-0684
4. SUPPLY PUMP 105220-7290
5. AUTOM. ADVANCE MECHANIS 105622-1590
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:

101491-0104 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 614 269 9400614269
ZEXEL 101491-0104 1014910104
ISUZU 5156013935 5156013935


Zexel num
Bosch num
Firm num
Name
101491-0104 
101491-0570 
9 400 614 269 
5156013935  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   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(10.2)
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   D
Rack position   R1+0.8
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   40.7 36.7 44.7
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   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

Test data 101491-0104
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=55
----------

Speed control lever angle

Test data 101491-0104
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=5.5deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101491-0104
N:Pump normal S:Stop the pump.
----------

----------
a=35deg+-5deg b=40deg+-5deg

Timing setting

Test data 101491-0104
(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)




Information:

Governor Actuator Mounting Replacement:
Removal Of The Previous Assembly
1. Disconnect linkage from cylinder and fuel pump, disassemble bracket from fuel pump lever.2. Remove cylinder from mounting plate, twist out rod end from cylinder.3. Remove mounting plate.Installing Of The New Linkage
1. Install 1433909, 8T4908, 8T4224, 9X6032, 8T4121 Linkage Assembly to engine block.2. Screw in U-joint of 1233885 Cylinder Rod as close as possible, tighten with 1426000 Nut, assemble cylinder with 8T1160 Bolts to the hinge.3. Assemble lever with washer and lock nut (1392085, 8T0389, 1392082, 8T4121), check free movement.4. Disconnect electrical connector from cylinder, turn on ignition, so that cylinder extends.5. Ensure pre-adjustment (overlapping of 1 mm) of U-joint and lever using the 8T4195 Stop Screw; tighten screw with nut (8T4133); See Illustration 2.6. Connect electrical connector to the cylinder and link up rod and lever with the 1233884 Pin.
Illustration 2Calibration
All adjustments have to be done with machine / engine at operating temperature
1. Start the engine.2. Plug-in PDT (portable diagnostic tool), choose menu "PROC" number 5 "ENGINE RPM" and number 6 "RPM DIFFERENCE". High And Low Idle Adjustment At Injection Pump:
1. Actuate the lever of the fuel injection pump by hand and adjust high and low idle by turning the corresponding stop screw at the fuel injection pump. If necessary fix the lever in the high idle position by use of a light spring to make adjustment easier:Set low idle to: 750 Rpm -20/+0 RpmSet high idle to : 2400 Rpm -0/+20 Rpm2. Make sure that when this is set a 1 mm spacer is fitted between the throttle lever and the high idle adjustment screw (see Illustration 3).3. Secure stop screw with locking nut. Seal setting with lockwire and lead seal, use your CAT dealer identification pliers.4. Disconnect electrical connector from the actuator (actuator piston extends completely).5. Stop the engine.6. Assemble and connect the 1413978 or 1397394, 9X8256, 1400277, 6V7743, 5C2890, 1107299, 1396903 Adjustable Rod, use the center hole at the fuel injection pump lever. Make sure that there is no contact between the fuel injection pump lever and the stop screw at high idle position.7. Start the engine.8. Adjust high idle setting with the rod:M312: high idle 2150 Rpm -0/+20 Rpm.M315: high idle 2400 Rpm -0/+20 Rpm.9. Secure the rod with the nuts at the ball joints.10. Mark the lock nut positions at the ball joints with a paint dot or using a felt-tip pen.11. Connect the electrical connector to the actuator.
Illustration 3Calibration/Adjustment Of The Engine
1. Press "F 1" key at the PDT for calibration.2. Choose item number 2 "CALIBRATION".3. Choose item number 1 "SPEED DIAL CAL".4. "MIN POSITION" setting, turn potentiometer on the panel until you receive the minimum voltage shown in the screen, press "ENTER".5. "MAX POSITION" setting, turn potentiometer until you receive maximum voltage shown in the screen, press "ENTER".6. You automatically get back into the previous menu, now choose number 2 "SPEED CAL".7. Change the low idle setting to 1020 Rpm by using the "UP- "or "DOWN-ARROW" keys at the PDT, when finished,

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Group cross 101491-0104 ZEXEL

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101491-0104  

101491-0570 
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4BC2
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