106991-1892 ZEXEL 9 400 618 797 BOSCH INJECTION-PUMP ASSEMBLY 9400618797 1069911892 1156031902

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 618 797 9400618797

ZEXEL 106991-1892 1069911892

ISUZU 1156031902 1156031902

Service parts 106991-1892 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106099-9670

3. GOVERNOR 105923-2880

4. SUPPLY PUMP 105237-5270

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

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:

106991-1892 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 797 9400618797

ZEXEL 106991-1892 1069911892

ISUZU 1156031902 1156031902

Zexel num

Bosch num

Firm num

Name

106991-1892

9 400 618 797

1156031902 ISUZU

INJECTION-PUMP ASSEMBLY
10PE1HRA K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

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 11.4

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 148 146.4 149.6

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 6.6+-0.5

Pump speed r/min 405 405 405

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(11.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 148 147 149

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.95

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 142 138 146

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=AD65
----------

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=41mm
----------
a=25.5deg+-5deg b=(34deg)+-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=740r/min Ra=R1(11.4)+0.05mm Vist=1.66+-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)