101492-0991 ZEXEL 9 400 611 503 BOSCH INJECTION-PUMP ASSEMBLY 9400611503 1014920991 8972142952

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 503 9400611503

ZEXEL 101492-0991 1014920991

ISUZU 8972142952 8972142952

Service parts 101492-0991 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-5130

3. GOVERNOR 105400-8841

4. SUPPLY PUMP 105220-6560

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-1220

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6721

11. Nozzle and Holder 8-97211-280-0

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

13. NOZZLE-HOLDER 105048-3230

14. NOZZLE

105017-2690

15. NOZZLE SET

Include in #1:

101492-0991 as INJECTION-PUMP ASSEMBLY

106692-9040 as _

Cross reference number

BOSCH 9 400 611 503 9400611503

ZEXEL 101492-0991 1014920991

ISUZU 8972142952 8972142952

Zexel num

Bosch num

Firm num

Name

101492-0991
101492-0992

9 400 611 503

8972142952 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 8.4

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 54 53 55

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.8+-0.5

Pump speed r/min 500 500 500

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 from N = N1
----------
K=10 N1=700r/min
----------

Speed control lever angle

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

----------
a=0deg+-5deg b=16deg+-5deg c=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=2.5deg+-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=12deg
----------
a=(210deg)