106991-1862 ZEXEL 9 400 612 289 BOSCH INJECTION-PUMP ASSEMBLY 9400612289 1069911862 1156031762

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 289 9400612289

ZEXEL 106991-1862 1069911862

ISUZU 1156031762 1156031762

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Buy INJECTION-PUMP ASSEMBLY 106991-1862 zexel genuine, new aftermarket engine parts with delivery

Service parts 106991-1862 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106099-9650

3. GOVERNOR 105923-2820

4. SUPPLY PUMP 105237-5280

5. AUTOM. ADVANCE MECHANIS 105693-0530

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7750

11. Nozzle and Holder 1-15300-328-0

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:

106991-1862 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 289 9400612289

ZEXEL 106991-1862 1069911862

ISUZU 1156031762 1156031762

Zexel num

Bosch num

Firm num

Name

106991-1862

9 400 612 289

1156031762 ISUZU

INJECTION-PUMP ASSEMBLY
10PE1-N K 14CE INJECTION PUMP ASSY 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 105780-8250

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 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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

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 1-8 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 -

Rack position 11.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 131.5 129.9 133.1

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

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.8)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 131.5 130.5 132.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.9

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 126 122 130

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=AD47
----------

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 set position 'H'
----------
aa=42.5mm
----------
a=22.5deg+-5deg b=(28deg)+-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=790r/min Ra=R1(11.8)+0.2mm Vist=1.55+-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:

Lubrication System
Oil Lubrication Schematic
Oil Pump
(1) Strainer. (2) Oil Pump relief valve. (3) Oil pump. (4) Idler gear. (5) Crankshaft gear.The lubrication system is the pressure type and the flow of oil goes from the oil pan through strainer (1) into oil pump (3). Oil pump (3) is driven by crankshaft gear (5) through idler gear (4). The oil pump is connected to the front main bearing cap. Relief valve (2) which is spring loaded controls the maximum oil pressure. An oil pressure sending unit is connected to the main oil gallery.Oil under pressure goes from the oil pump through the relief valve and filter. On the T4.236 Engines, oil passes first through the oil cooler. The oil cooler is cooled by water from the cooling system. On engines that have a center mounted balancer unit, the oil pump and relief valve are integral with the balancer unit.Oil flows through the filter to the main oil gallery which is a drilled passage the length of the crankcase. A pipe from the filter head feeds oil to the turbocharger bearings on T4.236 Engines.From the gallery the oil flows through drilled passages to the main bearing bores and then through the crankshaft passages to the big end (rod) bearings. T4.236 Engine oil also flows from the main oil gallery to the piston cooling jets which have integral relief valves. The piston cooling jets feed oil to the underside of the pistons, where the oil circulates, taking heat from the combustion area. The cooling jets start operation at approximately 205 kPa (30 psi).
Timing Gears
(6) Idler gear. (7) Idler gear retainer plate.The crankshaft bearings are lubricated from numbers 1, 3 and 5 main bearings. The camshaft center bearing supplies a controlled amount of oil to the rocker shaft assembly. Oil from the rocker shaft drains through a bleed hole in each rocker lever to lubricate the valves and valve guides.Oil also goes from the gallery through the rear of idler gear (6) hub, then through passages to lubricate the idler gear bearing and gear retainer plate (7).Pistons, cylinder liners, connecting rod small end bushings, cam lobes and tappets (valve lifters) are splash and oil mist lubricated.Balancer Unit
Center Mounted Balancer Unit Components
(1) Idler gear hub. (2) Idler gear bearing. (3) Idler gear. (4) Idler gear thrust washer. (5) Balance weight bushings. (6) Balance weights. (7) Oil transfer cover plate. (8) Balancer frame. (9) Oil pump relief valve assembly. (10) Balance weights drive gear. (11) Gear shaft drive bearings. (12) Gear shaft drive. (13) Oil pump. (14) Oil suction pipe.Engines that are mounted stationary (rigid) have a balancer unit that is mounted to the block bottom face in the center of the engine. The balancer unit is timed to and driven by the crankshaft through a gear on the crankshaft and idler gear (3). The rotation of timed balance weights (10) counteracts the movement of the pistons and connecting rods of the engine.Oil pump (13) is part of and is driven by the balancer unit