106891-1522 ZEXEL 9 400 618 561 BOSCH INJECTION-PUMP ASSEMBLY 9400618561 1068911522 1156031822


106891-1522 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 618 561 9400618561
ZEXEL 106891-1522 1068911522
ISUZU 1156031822 1156031822

Cross reference number

BOSCH 9 400 618 561 9400618561
ZEXEL 106891-1522 1068911522
ISUZU 1156031822 1156031822


Zexel num
Bosch num
Firm num
Name
106891-1522 
9 400 618 561 
1156031822  ISUZU
INJECTION-PUMP ASSEMBLY
8PE1-N 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   1-8-7-3- 6-5-4-2
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.   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   -
Rack position   11.8
Pump speed r/min   1110 1110 1110
Average injection quantity mm3/st.   113.5 111.9 115.1
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   500 500 500
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   1110 1110 1110
Average injection quantity mm3/st.   113.5 112.5 114.5
Basic   *
Fixing the lever   *

Test data Ex:

Governor adjustment

Test data 106891-1522
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=AG28
----------

Timer adjustment

Test data 106891-1522
(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

Test data 106891-1522
F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=56mm
----------
a=25.5deg+-5deg b=(33.5deg)+-3deg

Stop lever angle

Test data 106891-1522
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

Test data 106891-1522
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=1110r/min Ra=R1(11.8)mm Vist=1.59+-0.14V
----------

0000001601 AIR CYLINDER

Test data 106891-1522
(a) Air cylinder (b) Speed lever (c) Lock nut 1. Air cylinder adjustment procedure (1)Fix the speed lever (b) at the idle side. (2)Screw in the air cylinder (a) (3)Set the clearance between the speed lever (b) and the air cylinder (a) to approximately L1.
----------
L1=1mm
----------

0000001701 SPEED SENSOR

Test data 106891-1522
(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
----------

Timing setting

Test data 106891-1522
(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)




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