106891-1500 ZEXEL 9 400 619 988 BOSCH INJECTION-PUMP ASSEMBLY 9400619988 1068911500 1156031180

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 988 9400619988

ZEXEL 106891-1500 1068911500

ISUZU 1156031180 1156031180

Service parts 106891-1500 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP

3. GOVERNOR 105488-2320

4. SUPPLY PUMP 105237-4960

5. AUTOM. ADVANCE MECHANIS 105687-0551

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7851

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-4831

14. NOZZLE

105015-8200

15. NOZZLE SET

Include in #1:

106891-1500 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 988 9400619988

ZEXEL 106891-1500 1068911500

ISUZU 1156031180 1156031180

Zexel num

Bosch num

Firm num

Name

106891-1500
106891-1501

9 400 619 988

1156031180 ISUZU

INJECTION-PUMP ASSEMBLY
8PE1 * 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 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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-7-3- 6-5-4-2

Pre-stroke mm 4.2 4.17 4.23

Rack position
Point A R=A

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25

Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 7.8

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 101 99.5 102.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.8

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 100 96 104

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 4.7+-0.5

Pump speed r/min 265 265 265

Average injection quantity mm3/st. 10 8.7 11.3

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Timer adjustment

Pump speed r/min 800--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Damper spring setting: DL (3)Variable speed specification: idling adjustment (4)Main spring setting
----------
DL=3.7-0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=150mm
----------
a=5deg+-5deg b=(15deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=29.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side (2)Use the pin at R = aa
----------
aa=23.5mm
----------
a=40deg+-5deg b=73deg+-5deg

0000001201

(1)Variable speed specification (2)Minimum - maximum speed specification (3)Use the hole at R = aa
----------
aa=130mm
----------
a=13deg+-5deg b=26deg--

0000001501 ACS

(A) Set screw (B) Push rod 1 1. Aneroid compensator unit adjustment (1)Screw in (A) to obtain L1. 2. Adjustment following governor installation (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
----------
N1=1150r/min L1=0.1~0.5mm
----------
R1=7.8mm R2=7.1mm P1=(89.8)kPa((674)mmHg) P2=69.8+-0.7kPa(524+-5mmHg) Q1=(120.5)+-2cm3/1000st Q2=(104)cm3/1000st

0000001601 LEVER

2-stage changeover lever adjustment (A) Speed lever (B) Load lever (C) 2-stage changeover lever (D) Link (E) Bolt 1. Minimum-maximum speed specification adjustment (when running) (1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper. (2)In this condition, the load lever is held in the idle position. (3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L. (4)Lock using the nut. 2. Variable speed specification adjustment (at operation) (1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.) (2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
----------
L=1~2mm
----------

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=12deg
----------
a=(170deg)