101402-7860 ZEXEL 9 400 612 105 BOSCH INJECTION-PUMP ASSEMBLY 9400612105 1014027860 8972874770

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 105 9400612105

ZEXEL 101402-7860 1014027860

ISUZU 8972874770 8972874770

Service parts 101402-7860 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9560

3. GOVERNOR 105400-9350

4. SUPPLY PUMP 105220-5850

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-5020

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6811

11. Nozzle and Holder 8-97238-978-0

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

13. NOZZLE-HOLDER 105048-3230

14. NOZZLE 105017-2880

15. NOZZLE SET

Include in #1:

101402-7860 as INJECTION-PUMP ASSEMBLY

106671-4162 as _

Cross reference number

BOSCH 9 400 612 105 9400612105

ZEXEL 101402-7860 1014027860

ISUZU 8972874770 8972874770

Zexel num

Bosch num

Firm num

Name

101402-7860
101402-7861

9 400 612 105

8972874770 ISUZU

INJECTION-PUMP ASSEMBLY
4JG1 * 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 131424-0820

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 2.6 2.55 2.65

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 8.3

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 60.5 59.5 61.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.5+-0.5

Pump speed r/min 585 585 585

Average injection quantity mm3/st. 11.5 9.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Main spring setting (5)Rack difference between N = N1 and N = N2
----------
K=11 N1=1150r/min N2=900r/min
----------

Speed control lever angle

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

----------
a=6deg+-5deg b=18deg+-5deg c=31deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=11.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'W' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(210deg)