101492-0540 ZEXEL 9 400 614 395 BOSCH INJECTION-PUMP ASSEMBLY 9400614395 1014920540 8943879130

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 395 9400614395

ZEXEL 101492-0540 1014920540

ISUZU 8943879130 8943879130

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Service parts 101492-0540 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8740

3. GOVERNOR 105419-0500

4. SUPPLY PUMP 105220-4772

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-2020

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5121

11. Nozzle and Holder 5-15300-115-1

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4740

15. NOZZLE SET

Include in #1:

101492-0540 as INJECTION-PUMP ASSEMBLY

106675-4313 as _

Cross reference number

BOSCH 9 400 614 395 9400614395

ZEXEL 101492-0540 1014920540

ISUZU 8943879130 8943879130

Zexel num

Bosch num

Firm num

Name

101492-0540

9 400 614 395

8943879130 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

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 3.4 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 A

Rack position 9

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 50.7 49.7 51.7

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.9+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10 8.5 11.5

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 65 75

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting (5)Rack difference between N = N1 and N = N2
----------
K=8 N1=1250r/min N2=700r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=83deg+-5deg b=40deg+-3deg c=23deg+-5deg

Stop lever angle

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

----------
a=19deg+-5deg b=53deg+-5deg

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=(90deg)

Information:

1. Disconnect air line (1) from the fuel ratio control.2. Remove wire seal (4) from the bolts.3. Remove bolts (3) that hold fuel ratio control (2).4. Remove the fuel ratio control by pulling down and out from the collar. The following steps are for the installation of the fuel ratio control.5. Put fuel ratio control (2) in position on the governor. Make sure the valve head of the fuel ratio control is connected in the groove of the collar.6. Install bolts (3) that hold the fuel ratio control to the governor. Connect air line (1) to the fuel ratio control.7. To make an adjustment to the fuel ratio control, see the topic "Governor Adjustment For The Air Fuel Ratio Control" in, Testing & Adjusting Manual SENR6471.8. Install wire seal (4) on the bolts with Tool (A).Disassemble & Assemble Fuel Ratio Control
Start By:a. remove fuel ratio control 1. Put Tool (A) in a vise so that the station being used is not over the vise jaw. Place the fuel ratio control over the pins in Tool (A). Remove bolts (3) and remove cover (26) and gasket (24).
There is spring force behind cover (7). Hold cover (7) in position, and slowly remove the bolts that hold it to release the spring force.
2. Remove bolts (6). Remove cover (7) from housing (10).3. Remove nut (5) and stop (4) from cover (7).4. Remove spring (8), washer (9) and diaphragm (21) from retainer (25). Remove retainer (25) from housing (10).5. Remove tube (1) from the end of extension (19). Remove nut (2) from extension (19) and remove the extension from retainer (25). Remove valve (16), spring (22) and O-ring seal (23) from the extension.6. Remove spring (20), retainer (18) and spring (17) from housing (10).7. Remove piston (12) and valve assembly (14) from the housing.8. Use Tool (B) and remove snap ring (13) and washer (15) from the valve assembly. Remove piston (12) from the valve assembly.9. Remove seal (11) from piston (12).10. If necessary, remove the stem portion from valve assembly (14).11. Clean and inspect all parts. Make a replacement of all parts that are worn and damaged. The following steps are for the assembly of the fuel ratio control.12. If removed during disassembly, assemble the stem portion of valve assembly (14) on the valve using 9S3265 Retaining Compound.13. Lubricate seal (11) lightly with the lubricant being sealed. Put seal (11) on piston (12) and put piston (12) on valve assembly (14).14. Put washer (15) in position on the valve assembly and use Tool (B) to install snap ring (13) on the valve assembly.15. Place housing (10) on Tool (A), and put Tool (C) into the bore of the housing. Lubricate Tool (C) with clean engine oil.16. Push piston (12) into position with a smooth swift motion. Remove Tool (C) from the housing. Place spring (17), retainer (18) and spring (20) in housing (10).17. Put O-ring seal (23) on extension (19). Put spring (22) and valve (16) in position on the