101492-0840 ZEXEL 9 400 610 542 BOSCH INJECTION-PUMP ASSEMBLY 9400610542 1014920840 8971762010

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 542 9400610542

ZEXEL 101492-0840 1014920840

ISUZU 8971762010 8971762010

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Service parts 101492-0840 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-5100

3. GOVERNOR 105400-8550

4. SUPPLY PUMP 105220-7270

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-1720

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6211

11. Nozzle and Holder 8-97134-524-0

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

13. NOZZLE-HOLDER 105048-3230

14. NOZZLE

105017-2030

15. NOZZLE SET

Include in #1:

101492-0840 as INJECTION-PUMP ASSEMBLY

103684-0361 as _

Cross reference number

BOSCH 9 400 610 542 9400610542

ZEXEL 101492-0840 1014920840

ISUZU 8971762010 8971762010

Zexel num

Bosch num

Firm num

Name

101492-0840

9 400 610 542

8971762010 ISUZU

INJECTION-PUMP ASSEMBLY
4JB1 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 131424-0820

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 3.3 3.25 3.35

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 A

Rack position 7.8

Pump speed r/min 1225 1225 1225

Average injection quantity mm3/st. 53.5 52.5 54.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.6+-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
----------
K=10
----------

Speed control lever angle

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

----------
a=11deg+-5deg b=19deg+-5deg c=35deg+-3deg

Stop lever angle

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

----------
a=0deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'V' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(210deg)

Information:

There are two water temperature regulators, one for each cylinder head.1. Drain the coolant from the engine to a level below the water temperature regulators.
Typical Example2. Remove elbow (1). Remove tube and elbow (2). 3. Remove cover assemblies (3). 4. Remove water temperature regulator (4) from each cover assembly. 5. Remove lip-type seal (5) from each cover assembly if a replacement is necessary.6. Check the water temperature regulators. See Specifications Manual SENR6475. The following steps are for the installation of the water temperature regulators. 7. Use Tool (A) to install lip-type seals (5). Install the seals with the lip toward the inside of the covers. Install the seal until it contacts the counterbore in the cover assembly.
If the water temperature regulators are installed incorrectly the engine will over heat.
8. Put clean glycerin on the lip of seal (5), and install water temperature regulator (4) in each cover assembly (3). 9. Install new gaskets (6) and cover assemblies (3).
Typical Example10. Install the gaskets and elbow (1). Put clean engine oil or glycerin on the O-ring seals on tube (2). Install the gasket, tube and elbow (2).11. Fill the cooling system to the correct level. See the Operation & Maintenance Manual.