106991-1991 ZEXEL 9 400 612 791 BOSCH INJECTION-PUMP ASSEMBLY 9400612791 1069911991 1156032031

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 791 9400612791

ZEXEL 106991-1991 1069911991

ISUZU 1156032031 1156032031

Service parts 106991-1991 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106099-9700

3. GOVERNOR 105488-2160

4. SUPPLY PUMP 105237-5150

5. AUTOM. ADVANCE MECHANIS 105687-0730

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7851

11. Nozzle and Holder 1-15300-204-1

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.1{225}

13. NOZZLE-HOLDER 105031-4831

14. NOZZLE

105015-8200

15. NOZZLE SET

Include in #1:

106991-1991 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 791 9400612791

ZEXEL 106991-1991 1069911991

ISUZU 1156032031 1156032031

Zexel num

Bosch num

Firm num

Name

106991-1991
106991-1992

9 400 612 791

1156032031 ISUZU

INJECTION-PUMP ASSEMBLY
10PE1-S * K 14CE PE10P 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 8-3-600

Overflow valve 134424-4320

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 1-8-7-6- 5-4-3-10 -9-2

Pre-stroke mm 4.2 4.17 4.23

Rack position
Point A R=A

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 27 26.75 27.25

Difference between angles 2
Cal 1-7 deg. 72 71.75 72.25

Difference between angles 3
Cal 1-6 deg. 99 98.75 99.25

Difference between angles 4
Cal 1-5 deg. 144 143.75 144.25

Difference between angles 5
Cal 1-4 deg. 171 170.75 171.25

Difference between angles 6
Cal 1-3 deg. 216 215.75 216.25

Difference between angles 7
Cal 1-10 deg. 243 242.75 243.25

Difference between angles 8
Cal 1-9 deg. 288 287.75 288.25

Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 7.6

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 95.5 94 97

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.35+-0. 1

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 89.5 85.5 93.5

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 4.7+-0.5

Pump speed r/min 265 265 265

Average injection quantity mm3/st. 10.5 9.2 11.8

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Timer adjustment

Pump speed r/min [N1+50]- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min N1

Advance angle deg. 0 0 0

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 3.5 3 4

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Damper spring setting: DL
----------
RT=0.8 TH=1.7mm DL=3.7-0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=7deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=26deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Drive side
----------
aa=23.5mm
----------
a=73deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Set screw 1. Aneroid compensator unit adjustment Screw in (A) to obtain L1. 2. Adjustment following governor installation (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.
----------
N1=1150r/min L1=(0.1~0.5)mm
----------
R1=(7.6)mm R2=6.9mm P1=(89.8)kPa((674)mmHg) P2=69.8+-0.7kPa(524+-5mmHg) Q1=112+-4cm3/1000st Q2=96+-10cm3/1000st

Timing setting

(1)Pump vertical direction (2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side) (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(170deg)