101492-0992 ZEXEL 9 400 611 318 BOSCH INJECTION-PUMP ASSEMBLY 9400611318 1014920992 8972142953

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 318 9400611318

ZEXEL 101492-0992 1014920992

ISUZU 8972142953 8972142953

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Buy INJECTION-PUMP ASSEMBLY 101492-0992 zexel genuine, new aftermarket engine parts with delivery

Service parts 101492-0992 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:

101492-0992 as INJECTION-PUMP ASSEMBLY

103664-1322 as _

Cross reference number

BOSCH 9 400 611 318 9400611318

ZEXEL 101492-0992 1014920992

ISUZU 8972142953 8972142953

Zexel num

Bosch num

Firm num

Name

101492-0992

9 400 611 318

8972142953 ISUZU

INJECTION-PUMP ASSEMBLY
4JG1 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 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 fuel lines (1) from fuel transfer pump (3). Remove bolts (2). Remove fuel transfer pump (3). Remove gasket from fuel transfer pump.2. Install a new gasket on fuel transfer pump (3). Install fuel transfer pump on rear plate with the bolts (2) that hold it. Connect fuel lines (1) to the fuel transfer pump.Disassemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Remove tachometer drive (3) from transfer pump cover (4).2. Remove bolts (1). Make a separation between cover (4) and pump body (2). 3. Remove lip-type seal (6) from the cover. Remove plug (5), seal, spring and plunger (bypass valve) from the cover. 4. Remove nut (10) from shaft (7). Remove gear (9) and key (11).5. Remove shaft (7) and gear (8) as a unit. Remove gear (8) from drive shaft (7) with a press.6. Remove idler gear (12). 7. Remove bushing (14), two lip-type seals and the bottom bearing from pump body (1).8. Remove check valve (13). Assemble Fuel Transfer Pump
1. Install bushing (4) in body (3) with Tooling (B). The bushing must not be extended above the (gear) surface of the body.2. Install the check valve in the body with Tooling (A).3. Install lip-type seal (5) with Tooling (C). Install the seal until it is 24.6 0.5 mm (97 .02) from the bottom surface of body (3) and with the lip toward bushing (4) as shown.4. Install lip-type seal (6) with Tooling (D). Install the seal until it is 14.2 0.5 mm (.56 .02 in) from the bottom surface of body (3) and with the lip away from seal (5) as shown.5. Install bearing (7) in body (3) with Tooling (E). The bearing must be even with the surface of the pump body. 6. Heat gear (8) to a maximum temperature of 316°C (600°F). Install gear (8) on shaft (11) until dimension (X) is 49.71 0.25 mm (1.957 0.10 in).7. Install the drive shaft and gear in body (3). Install key, gear (10) and nut (9). Tighten the nut to a torque of 28 7 N m (22 5 lb ft).8. Install idler gear (12) in body (3).9. Install lip-type seal (2) with Tooling (C). Install the seal until it is 3.8 0.5 mm (.15 .02 in) from the top surface of cover (1) with the lip toward the inside as shown. 10. Install plunger (14) (bypass valve), spring (15), seal plug (13) in pump cover (1). Tighten plug (13) to a torque of 28 4 N m (27 3 lb ft).11. Put 7M-7260 Liquid Gasket Material on the surface of cover (1). Install cover (1) on pump body.
Do not let the liquid gasket enter the pump.
The drive shaft must turn freely after the bolts that hold the transfer pump together are tightened.12. Install tachometer drive on transfer pump cover (1).End By:a. install fuel transfer pump