106991-1852 ZEXEL 9 400 618 794 BOSCH INJECTION-PUMP ASSEMBLY 9400618794 1069911852 1156031742

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 794 9400618794

ZEXEL 106991-1852 1069911852

ISUZU 1156031742 1156031742

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Buy INJECTION-PUMP ASSEMBLY 106991-1852 zexel genuine, new aftermarket engine parts with delivery

Service parts 106991-1852 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106099-9640

3. GOVERNOR 105923-2800

4. SUPPLY PUMP 105237-5280

5. AUTOM. ADVANCE MECHANIS 105693-0540

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7750

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105030-3540

14. NOZZLE 105025-0090

15. NOZZLE SET

Include in #1:

106991-1852 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 794 9400618794

ZEXEL 106991-1852 1069911852

ISUZU 1156031742 1156031742

Zexel num

Bosch num

Firm num

Name

106991-1852

9 400 618 794

1156031742 ISUZU

INJECTION-PUMP ASSEMBLY
12PE1-N K 14CC INJECTION PUMP ASSY PE12P PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 134424-4320

Overflow valve opening pressure kPa 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-9-8- 5-2-11-1 0-3-6-7-

Pre-stroke mm 5.5 5.47 5.53

Rack position
Point A R=A

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-4 deg. 15 14.75 15.25

Difference between angles 2
Cal 1-9 deg. 60 59.75 60.25

Difference between angles 3
Cal 1-8 deg. 75 74.75 75.25

Difference between angles 4
Cal 1-5 deg. 120 119.75 120.25

Difference between angles 5
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 6
Cal 1-11 deg. 180 179.75 180.25

Difference between angles 7
Cal 1-10 deg. 195 194.75 195.25

Difference between angles 8
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 9
Cal 1-6 deg. 255 254.75 255.25

Difference between angles 10
Cal 1-7 deg. 300 299.75 300.25

Difference between angles 11
Cal 1-12 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point -

Rack position 11.9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 135 133.4 136.6

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 6.5+-0.5

Pump speed r/min 430 430 430

Average injection quantity mm3/st. 13.5 11.5 15.5

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.9)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 135 134 136

Max. variation between cylinders % 0 -13 13

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.8

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 132 128 136

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Damper spring setting
----------
T1=AD37
----------

Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(8)deg t1=1.5--sec t2=1.5--sec
----------
N1=950++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt setting
----------
aa=42.5mm
----------
a=22.5deg+-5deg b=(31deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=20deg+-5deg b=43deg+-5deg

0000001501 RACK SENSOR

Rack sensor adjustment 1. Flange type rack sensor (rack sensor adjustment -5*20) (1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures. (2)Mount the rack sensor main body to the pump main body. (3)Fix the pump lever at full. (4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist. (5)Move the pump lever two or three times. (6)Set again to full. (7)Confirm that the amplifier output voltage is Vist. (8)Fix the caution plate to the upper part of the rack sensor. (For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.) (9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=750r/min Ra=R1(11.9)mm Vist=1.57+-0.14V
----------

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=4deg
----------
a=(180deg)

Information:

4.236 Engines
(1) Inside diameter of rod for small end bushing ... 38.8938 to 38.9192 mm (1.53125 to 1.53225 in)(2) Outside diameter of bushing for piston pin ... 38.989 to 39.027 mm (1.5350 to 1.5365 in) Inside diameter of bushing for piston pin (after reaming) ... 34.9441 to 34.9631 mm (1.37575 to 1.37650 in)Clearance between small end bushing and piston pin ... 0.0191 to 0.0432 mm (.00075 to .00170 in)(3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to 219.10 mm (8.624 to 8.626 in)(4) Outside diameter of connecting rod bearing ... 67.221 mm (2.6465 in) Inside diameter of connecting rod bearing (standard) ... 63.520 to 63.548 mm (2.5008 to 2.5019 in)Bearings available for reground (machined) journals of crankshaft with undersize ... 0.25, 0.51 and 0.76 mm (.010, .020 and .030 in)Shell thickness ... 1.836 to 1.844 mm (.0723 to .0726 in)(5) Inside diameter of rod for big end bearing ... 67.208 to 67.221 mm (2.6460 to 2.6465 in)(6) Torque for connecting rod nuts: Cadmium plated nuts (silver color) ... 100 N m (75 lb ft)Phosphated nuts (dull black color) ... 130 N m (95 lb ft)T4.236 Engines
(1) Inside diameter of rod for small end bushing ... 42.0688 to 42.0942 mm (1.65625 to 1.65725 in)(2) Outside diameter of bushing for piston pin ... 42.1577 to 42.1958 mm (1.65975 to 1.66125 in) Inside diameter of bushing for piston pin (after reaming) ... 38.1191 to 38.1381 mm (1.50075 to 1.50150 in)Clearance between small end bushing and piston pin ... 0.0191 to 0.0432 mm (.00075 to .00170 in)(3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to 219.10 mm (8.624 to 8.626 in)(4) Outside diameter of connecting rod bearing ... 67.221 mm (2.6465 in) Inside diameter of connecting rod bearing (standard) ... 63.520 to 63.548 mm (2.5008 to 2.5019 in)Bearings available for reground (machined) journals of crankshaft with undersize ... 0.25, 0.51 and 0.76 mm (.010, .020 and .030 in)Shell thickness ... 1.836 to 1.844 mm (.0723 to .0726 in)(5) Inside diameter of rod for big end bearing ... 67.208 to 67.221 mm (2.6460 to 2.6465 in)(6) Torque for connecting rod nuts: Cadmium plated nuts (silver color) ... 100 N m (75 lb ft)Phosphated nuts (dull black color) ... 130 N m (95 lb ft)