101491-0600 ZEXEL 9 400 614 296 BOSCH INJECTION-PUMP ASSEMBLY 9400614296 1014910600 8970251451

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 296 9400614296

ZEXEL 101491-0600 1014910600

ISUZU 8970251451 8970251451

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Buy INJECTION-PUMP ASSEMBLY 101491-0600 zexel genuine, new aftermarket engine parts with delivery

Service parts 101491-0600 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8870

3. GOVERNOR 105931-8161

4. SUPPLY PUMP 105210-5140

5. AUTOM. ADVANCE MECHANIS 105622-1631

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4683

11. Nozzle and Holder 8-97119-858-0

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

13. NOZZLE-HOLDER 105048-3352

14. NOZZLE

105017-0610

15. NOZZLE SET

Include in #1:

101491-0600 as INJECTION-PUMP ASSEMBLY

101602-3420 as _

Cross reference number

BOSCH 9 400 614 296 9400614296

ZEXEL 101491-0600 1014910600

ISUZU 8970251451 8970251451

Zexel num

Bosch num

Firm num

Name

101491-0600
101491-0670

9 400 614 296

8970251451 ISUZU

INJECTION-PUMP ASSEMBLY
4BE1 * 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

Overflow valve 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 3.2 3.15 3.25

Rack position
Point A R=A

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 10.7

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 58.1 56.5 59.7

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 9.7+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8 6.5 9.5

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(10.7)

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 58.1 57.1 59.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 70.2 67 73.4

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 78.5 62.5 94.5

Fixing the lever *

Timer adjustment

Pump speed r/min 1425--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1375

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1750

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)Tolerance for racks not indicated: +-0.05mm.
----------
T1=D60
----------

Speed control lever angle

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

----------
a=5.5deg+-5deg b=36deg+-3deg

Stop lever angle

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

----------
a=45deg+-5deg b=29deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 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)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=1050r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.7)mm Rb=R1-0.45mm Pa=95.5+-5.3kPa(716+-40mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=58.1cm3/1000st Q2=(44.5)+-1.6cm3/1000st

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=17deg
----------
a=(90deg)

Information:

Start By:a. remove radiator 1. Attach lifting strap to engine compartment cover. Remove two cotter pins and washers (1), remove four bolts (2). Lift off cover. 2. Loosen hose clamps (3) and (4) and remove hose (5). Remove three bolts (6) and remove ether aid cover (7). 3. Disconnect ether aid line (8), electrical connector (9), and loosen eight 1/4 turn fasteners (10). Remove heat shields (11) and (12). 4. Mark and disconnect starter wires (13) and ground strap (14). 5. Mark and disconnect alternator wires (15) and (16), temperature sending unit wire (17), cable mounting bracket (18), and electrical connector (19). Disconnect and remove flexible exhaust pipe (20). Disconnect two heater hoses (21). 6. Disconnect throttle linkage (22), remove two bolts (23). Set throttle linkage mounting bracket aside. Shut off and disconnect two fuel lines (24). 7. Disconnect throttle cable clip (25). Disconnect electrical wire (26), electrical connector (27) and governor wiring (28). 8. Install tool (A), lifting strap and tool (B) as shown, to support hydraulic pump. Remove twelve hydraulic pump mounting bolts (29). 9. Install lifting chains and remove four bolts and bushings (30).10. Remove engine. The following steps are to install the engine.11. Position engine in vehicle and install four bolts and bushings (30).12. Connect hydraulic pump to engine with twelve mounting bolts (29).13. Remove tooling (A) and (B), and the lifting strap that was supporting the hydraulic pump.14. Connect governor wiring (28), electrical connector (27), and wire (26). Connect throttle cable clip (25).15. Connect two fuel lines (24). Position throttle linkage mounting bracket and secure with two bolts (23). Connect throttle linkage (22).16. Connect two heater hoses (21) and flexible exhaust pipe (20). Connect alternator wires (15) and (16), temperature sending unit wire (17), cable mounting bracket (18) and electrical connector (19).17. Connect starter wires (13) and ground strap (14).18. Replace heat shields (11) and (12), fasten with eight 1/4 turn fasteners. Connect electrical connector (9) and ether aid line (8).19. Replace ether aid cover (7) and secure with three bolts (6). Replace hose (5) and connect with clamps (3) and (4).20. Attach engine compartment cover with four bolts (2) and connect cylinders with cotter pins and washers (1).End By:a. install radiator