Information injection-pump assembly
BOSCH
9 400 612 520
9400612520
ZEXEL
101402-7910
1014027910
ISUZU
8972611760
8972611760
Rating:
Service parts 101402-7910 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97222-170-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 612 520
9400612520
ZEXEL
101402-7910
1014027910
ISUZU
8972611760
8972611760
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 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-4920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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
1-3-4-2
Pre-stroke
mm
3.4
3.35
3.45
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.7
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
86
84.9
87.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.1+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
8.8
7.4
10.2
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
8.9++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
125
120
130
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
----------
K=14
----------
----------
K=14
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=1deg+-5deg b=20deg+-5deg c=35deg+-3deg
----------
----------
a=1deg+-5deg b=20deg+-5deg c=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=4.5deg+-5deg b=53deg+-5deg
----------
----------
a=4.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=9deg
----------
a=(100deg)
----------
aa=9deg
----------
a=(100deg)
Information:
start by:a) remove turbocharger 1. Make a mark on compressor housing (1), cartridge assembly (3) and the turbine housing (4) for correct installation. 2. Loosen clamp assembly (2). Remove compressor housing (1) and cartridge assembly (3) from the turbine housing.3. Remove bolts (6) and plates (5) that hold cartridge assembly in the compressor housing. Remove cartridge assembly (3). 4. Remove O-ring seal (7) from the cartridge assembly. 5. Put cartridge assembly (3) in position in tooling (A) and loosen nut on the compressor wheel with tooling (C).6. Remove nut (8) and the compressor wheel (9). 7. Remove shaft and wheel assembly (10) from the cartridge assembly. 8. Remove shroud (11) from the cartridge assembly. 9. Remove four bolts (12) and then remove backplate (13) from the cartridge assembly.10. Remove spacer (14) from the backplate. 11. Remove two seal rings (15) from the spacer. 12. Remove snap ring (16) from cartridge housing with tool (B). 13. Remove bearing (17) and rings from the cartridge housing.14. Remove snap ring (18) from cartridge housing with tool (B). 15. Turn the cartridge housing over and then remove screws (20), plate (21) and collar (19). 16. Remove bearing (22) from the cartridge housing. 17. Remove snap ring (23) from the cartridge housing with tool (B).Assemble Turbocharger
Make sure all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Put clean engine oil on all parts of the cartridge assembly. 1. Install snap ring (1) in the cartridge housing with tool (A). Make sure the oil hole in plate (5) is open and clean to prevent a bearing failure.2. Install bearing (2), collars (3), plate (5) and screws (4). Tighten the screws to
Make sure all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Put clean engine oil on all parts of the cartridge assembly. 1. Install snap ring (1) in the cartridge housing with tool (A). Make sure the oil hole in plate (5) is open and clean to prevent a bearing failure.2. Install bearing (2), collars (3), plate (5) and screws (4). Tighten the screws to