Information injection-pump assembly
BOSCH
9 400 619 988
9400619988
ZEXEL
106891-1500
1068911500
ISUZU
1156031180
1156031180
Rating:
Service parts 106891-1500 INJECTION-PUMP ASSEMBLY:
1.
_
2.
FUEL INJECTION PUMP
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:
106891-1500
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
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
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
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
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
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
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
----------
----------
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
----------
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
----------
----------
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
----------
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--
----------
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
----------
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
----------
----------
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)
----------
aa=12deg
----------
a=(170deg)
Information:
Right Side (6 Cylinder Shown)(1) Depth that cup plugs are installed (measured from block face to top edge of plug) ... 1.25 0.25 mm (.049 .010 in)(2) Distance all sleeves extend from top face ... 14 2 mm (.55 .08 in)(3) Distance two large dowels extend from rear face ... 12.0 0.5 mm (.47 .02 in)(4) Distance two small dowels extend from rear face ... 8.0 0.5 mm (.31 .02 in)(5) Distance all dowels extend from front face ... 8.0 0.5 mm (.31 .02 in)
View A-A (Rear Face)(6) Bores in block for all camshaft bearings except front bearing ... 69.000 0.038 mm (2.7165 .0015 in)(7) Locate bearing oil hole for all camshaft bearings (except front bearing) at top of bore.
Front Face(8) Bore in block for front camshaft bearing ... 70.000 0.025 mm (2.7559 .0010 in)(9) Front camshaft bearing joint location.(10) Front camshaft bearing oil hole. Install front camshaft bearing with bearing oil hole (10) aligned with oil hole in block and bearing joint (9) positioned as shown.(11) Width of main bearing cap ... 159.995 0.020 mm (6.2990 .0008 in) Width of cylinder block for main bearing cap ... 160.000 0.018 mm (6.2992 .0007 in)(12) Bore in block for main bearings ... 95.000 0.013 mm (3.7402 .0005 in)(13) Main bearing cap bolts. Install as follows: Install bearing caps with sequence number to the right, 1 through 5 (for 4 cylinder) or 1 through 7 (for 6 cylinder), front to rear.a. Before assembly, put 2P2506 Thread Lubricant on the bolt threads and washer face.b. Tighten both bolts of each bearing cap to a torque of ... 54 7 N m (40 5 lb ft)c. Then tighten bolts an additional ... 90 5 degrees (1/4 turn)(14) Location of bearing cap sequence number.(15) Dimension from centerline of crankshaft bore to pan rail ... 110.00 mm (4.331 in)(16) Dimension from centerline of crankshaft bore to top of block ... 322.00 .017 mm (12.677 .0007 in)(17) Cylinder bore size ... 105.025 .025 mm (4.1348 .0010 in) Bore size must be checked with a 4C4377 Cylinder Head Stress Plate and gasket installed. Refer to Installation Of 7C6208 Cylinder Sleeve, Special Instruction Form No. SEHS9047. (18) Piston cooling jet. Check piston cooling jets by inserting a 1.3 mm (.05 in) diameter drill rod into jet. Rod must pass through a 5.0 mm (.20 in) diameter circle in location (A) and a 13 mm (.51 in) diameter circle in location (B). Dimension (C) is 25.9 mm (1.02 in). Dimension (D) is 33.4 mm (1.31 in). Dimension (E) is 26.95 mm (1.061 in). Dimension (F) is 9.8 mm (.39 in). Dimension (G) is 50 mm (2.0 in). Distance four sleeves (19) extend from side face ... 5.0 0.5 mm (.20 .02 in)