Information injection-pump assembly
BOSCH
9 400 618 544
9400618544
ZEXEL
106891-1290
1068911290
ISUZU
1156025520
1156025520

Rating:
Service parts 106891-1290 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
15.7(160)/22.1(225)
15.
NOZZLE SET
Include in #1:
106891-1290
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 618 544
9400618544
ZEXEL
106891-1290
1068911290
ISUZU
1156025520
1156025520
Zexel num
Bosch num
Firm num
Name
106891-1290
9 400 618 544
1156025520 ISUZU
INJECTION-PUMP ASSEMBLY
8PD1-S * K
8PD1-S * K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve (drive side)
134424-4020
Overflow valve opening pressure (drive side)
kPa
255
221
289
Overflow valve opening pressure (drive side)
kgf/cm2
2.6
2.25
2.95
Overflow valve (governor side)
134424-2720
Overflow valve opening pressure (governor side)
kPa
255
221
289
Overflow valve opening pressure (governor side)
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25
Cal 1-3 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
8.5
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
110
108.5
111.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.8
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
111.6
109.6
113.6
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.9
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
117.4
115.4
119.4
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
4.9+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8.8
7.5
10.1
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Timer adjustment
Pump speed
r/min
600--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
550
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
800+-30
Advance angle
deg.
2
1.5
2.5
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
2
1.5
2.5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_05
Pump speed
r/min
1150
Advance angle
deg.
5.5
5
6
Remarks
Finish
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
----------
----------
----------
----------
Speed control lever angle

F:Full speed
----------
----------
a=7deg+-5deg
----------
----------
a=7deg+-5deg
0000000901

F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=70mm
----------
a=15deg+-5deg b=34deg+-3deg
----------
aa=70mm
----------
a=15deg+-5deg b=34deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=60deg+-5deg b=73deg+-5deg
----------
----------
a=60deg+-5deg b=73deg+-5deg
0000001501 RACK SENSOR

V1:Supply voltage
V2f:Full side output voltage
V2i:Idle side output voltage
(A) Black
(B) Yellow
(C) Red
(D) Trimmer
(E): Shaft
(F) Nut
(G) Load lever
1. Load sensor adjustment
(1)Connect as shown in the above diagram and apply supply voltage V1.
(2)Hold the load lever (G) against the full side.
(3)Turn the shaft so that the voltage between (A) and (B) is V2.
(4)Hold the load lever (G) against the idle side.
(5)Adjust (D) so that the voltage between (A) and (B) is V2i.
(6)Repeat the above adjustments.
(7)Tighten the nut (F) at the point satisfying the standards.
(8)Hold the load lever against the full side stopper and the idle side stopper.
(9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
0000001601 LEVER

(A) Load lever (for cruise control)
(B) idle stopper bolt
(C) accelerator lever stopper bolt
(D) Accelerator lever
1. Accelerator lever stopper bolt adjustment
(1)Hold the load lever A against the idle stopper bolt and fix.
(2)Push in the accelerator lever stopper bolt C to contact the accelerator lever D.
(3)From this position, back off the idle stopper bolt B N turns (L) and set.
----------
N=1~1.5 L=0.8~1.2mm
----------
----------
N=1~1.5 L=0.8~1.2mm
----------
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 (set timing)
(4)-
----------
aa=8deg
----------
a=(180deg)
----------
aa=8deg
----------
a=(180deg)
Information:
High Gear Turn On Speed:
Vehicle Speed where "High Gear RPM Limit" turns on. This must be matched to the specific drive train for best performance. Minimum 30 mphMaximum 127 mphDefault 127 mphEngine Parameters
Rating Number:
Number of rating within horsepower family. The Personality Module defines the horsepower family (such as 325 hp) and may contain several ratings within that family. The rating number defines which rating is used (such as 325 hp @ 1900 rpm or 325 hp @ 2100 rpm) within the family.Top Engine Limit:
Maximum engine rpm when the engine is under load. The engine will still achieve rated rpm under no load conditions. TEL is dependent upon the RATING number, with some RATING numbers allowing no or little variation as specified below. Minimum 1300 rpmMaximum 3000 rpmDefault 1820 rpmLow Idle RPM:
Minimum engine rpm. Minimum 600 rpmMaximum 750 rpmDefault 700 rpmIdle Shutdown Time:
Time (in minutes) that engine will idle before shutting down. Engine will only shutdown if 3176 sees no engine load, no vehicle speed, and the parking brake is set. If this parameter is programmed to zero, this feature is disabled and the engine will idle until the key switch is turned OFF. this feature does not shut down vehicle power - the ECM and vehicle remain powered. Minimum 3 min.Maximum 60 min.Default 0 min.Vehicle ID:
Identification of the vehicle assigned by the customer. Used only for customer reference: not required by the ECM.Engine Protection Parameters
Engine Protection Mode:
Determines the level of action taken by the ECM in response to a potentially engine damaging condition recognized by the Caterpillar Coolant Temperature, Oil Pressure, or OEM Coolant Level (if installed and enabled) Sensors. Default Alternative OFFAlternative DERATEAlternative SHUTDOWNCoolant Level Sensor Enable/Disable:
This feature is not available on Personality Modules for engines before OCT91. The ECAP will show NOT INSTALLED on the Customer Programmable Parameters screen for pre-OCT91 Personality Modules. If a newer Personality Module is replacing an older Personality Module, this feature must be DISABLED.Determines if the ECM monitors the Coolant Level Sensor inputs.Default ENABLEDAlternative DISABLEDPasswords
Factory Passwords
Factory passwords are required to perform each of the following four functions:1. Program a New ECM When an ECM is replaced, the System Configuration Parameters must be programmed into the new ECM. These parameters are protected by factory passwords.2. Rerate Engine to another Engine Family This requires changing the Personality Module Code, which is protected by factory passwords.3. Read Customer Passwords If the owner loses his customer passwords, he will not be able to program customer parameters. Using factory passwords, one can read customer passwords, then use those customer passwords to program customer parameters.4. Clear Certain Diagnostic Codes Only Diagnostic Code 190-00 (Engine Overspeed Warning) requires factory passwords to clear once it is logged. Certain other codes require customer passwords. The majority of logged codes require no passwords to clear.Since factory passwords contain alphabetic characters, only the ECAP may perform these functions. The DDT cannot because it does not have alphabetic character keys.To obtain factory passwords, proceed as if you already had the password. At some
Vehicle Speed where "High Gear RPM Limit" turns on. This must be matched to the specific drive train for best performance. Minimum 30 mphMaximum 127 mphDefault 127 mphEngine Parameters
Rating Number:
Number of rating within horsepower family. The Personality Module defines the horsepower family (such as 325 hp) and may contain several ratings within that family. The rating number defines which rating is used (such as 325 hp @ 1900 rpm or 325 hp @ 2100 rpm) within the family.Top Engine Limit:
Maximum engine rpm when the engine is under load. The engine will still achieve rated rpm under no load conditions. TEL is dependent upon the RATING number, with some RATING numbers allowing no or little variation as specified below. Minimum 1300 rpmMaximum 3000 rpmDefault 1820 rpmLow Idle RPM:
Minimum engine rpm. Minimum 600 rpmMaximum 750 rpmDefault 700 rpmIdle Shutdown Time:
Time (in minutes) that engine will idle before shutting down. Engine will only shutdown if 3176 sees no engine load, no vehicle speed, and the parking brake is set. If this parameter is programmed to zero, this feature is disabled and the engine will idle until the key switch is turned OFF. this feature does not shut down vehicle power - the ECM and vehicle remain powered. Minimum 3 min.Maximum 60 min.Default 0 min.Vehicle ID:
Identification of the vehicle assigned by the customer. Used only for customer reference: not required by the ECM.Engine Protection Parameters
Engine Protection Mode:
Determines the level of action taken by the ECM in response to a potentially engine damaging condition recognized by the Caterpillar Coolant Temperature, Oil Pressure, or OEM Coolant Level (if installed and enabled) Sensors. Default Alternative OFFAlternative DERATEAlternative SHUTDOWNCoolant Level Sensor Enable/Disable:
This feature is not available on Personality Modules for engines before OCT91. The ECAP will show NOT INSTALLED on the Customer Programmable Parameters screen for pre-OCT91 Personality Modules. If a newer Personality Module is replacing an older Personality Module, this feature must be DISABLED.Determines if the ECM monitors the Coolant Level Sensor inputs.Default ENABLEDAlternative DISABLEDPasswords
Factory Passwords
Factory passwords are required to perform each of the following four functions:1. Program a New ECM When an ECM is replaced, the System Configuration Parameters must be programmed into the new ECM. These parameters are protected by factory passwords.2. Rerate Engine to another Engine Family This requires changing the Personality Module Code, which is protected by factory passwords.3. Read Customer Passwords If the owner loses his customer passwords, he will not be able to program customer parameters. Using factory passwords, one can read customer passwords, then use those customer passwords to program customer parameters.4. Clear Certain Diagnostic Codes Only Diagnostic Code 190-00 (Engine Overspeed Warning) requires factory passwords to clear once it is logged. Certain other codes require customer passwords. The majority of logged codes require no passwords to clear.Since factory passwords contain alphabetic characters, only the ECAP may perform these functions. The DDT cannot because it does not have alphabetic character keys.To obtain factory passwords, proceed as if you already had the password. At some
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Isuzu
106891-1290
9 400 618 544
1156025520
INJECTION-PUMP ASSEMBLY
8PD1-S
8PD1-S