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

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 503 9400611503

ZEXEL 101492-0991 1014920991

ISUZU 8972142952 8972142952

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Buy INJECTION-PUMP ASSEMBLY 101492-0991 zexel genuine, new aftermarket engine parts with delivery

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)

Information:

1. Disconnect air line (1) at fitting. Remove two bolts (2). Pull up and toward the front of the engine to remove the bolt of the fuel ratio from the groove (slot) in the collar for the governor. Remove fuel ratio control (3). Remove gasket from fuel ratio control.2. Install a new gasket on fuel ratio control. Install fuel ratio control (3). Make sure bolt engages with stop collar in governor control.3. Install two bolts (2). Connect air line (1) at fitting.4. Make sure the fuel ratio control is in correct adjustment. See Systems Operation Testing & Adjusting Manual for this procedure.5. Install a new governor seal.Disassemble Fuel Ratio Control
Start By:a. remove fuel ratio control 1. Remove two bolts (1) and the housing (2). 2. Remove valve assembly (3).3. Remove seal (4) and O-ring seal from valve.4. Remove the retainer (5) and two springs (6). 5. Remove three bolts (9) and cover (10).6. Remove valve (7), diaphragm (8), retainer and spring. 7. Remove pin (12) from valve (7).8. Remove cover (11) from the valve.9. Remove the seal from the cover (11).Assemble Fuel Ratio Control
1. Put clean engine oil on lip of seal. Install the seal (1) in cover (2). Install seal so lip of seal is toward the inside of the cover. 2. Install the valve (3) into cover (2).3. Install the pin that holds cover on valve. 4. Install spring (7) and the retainer (6) in cover (8).5. Install diaphragm (5) on the valve assembly (4) and in the cover. 6. Install cover and three bolts (11) that hold covers together.7. Put clean engine oil on seal and ring seal. Install the seals (10) on valve.8. Install the two springs (13), retainer and valve assembly (12).9. Install housing (9) and two bolts.
Correct adjustment must be made to fuel ratio control before installation. See Systems Operation Testing & Adjusting for this procedure.
End By:a. install fuel ratio control