Information injection-pump assembly
BOSCH
9 400 610 143
9400610143
ZEXEL
101602-0620
1016020620
ISUZU
1156009241
1156009241
Rating:
Service parts 101602-0620 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-089-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 143
9400610143
ZEXEL
101602-0620
1016020620
ISUZU
1156009241
1156009241
Zexel num
Bosch num
Firm num
Name
101602-0620
9 400 610 143
1156009241 ISUZU
INJECTION-PUMP ASSEMBLY
6BD1T * K 14BE PE6A PE
6BD1T * K 14BE PE6A PE
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
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
1-5-3-6-
2-4
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 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.7
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
77.1
75.1
79.1
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Boost pressure
kPa
46.7
46.7
Boost pressure
mmHg
350
350
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.4
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
79.4
77.9
80.9
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
46.7
46.7
Boost pressure
mmHg
350
350
Injection quantity adjustment_03
Adjusting point
C
Rack position
8.1
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
55.4
53.4
57.4
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_04
Adjusting point
D
Rack position
5.2+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
12.7
11.4
14
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_05
Adjusting point
E
Rack position
9.2+-0.5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
58.2
58.2
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
8.1
Boost pressure
kPa
26.7
20
33.4
Boost pressure
mmHg
200
150
250
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
8.7
Boost pressure
kPa
40
37.3
42.7
Boost pressure
mmHg
300
280
320
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Boost compensator operation limit position: L1
(3)Set idle sub-spring
(4)Main spring setting
----------
K=15 L1=(10.5)mm
----------
----------
K=15 L1=(10.5)mm
----------
Speed control lever angle
F:Full speed
I:Idle
D:Dead point
(1)Stopper bolt setting
----------
----------
a=18deg+-1deg b=29deg+-5deg c=20deg+-3deg
----------
----------
a=18deg+-1deg b=29deg+-5deg c=20deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=46deg+-5deg
----------
----------
a=12deg+-5deg b=46deg+-5deg
0000001501 LEVER
1. Variable lever adjustment
(1)Fix lever (B) in the beginning of speed increase position using bolts (C) and (D).
(2)Fix using the bolt E so that the lever A is aa.
(3)Lock using bolt (G).
(4)After completing idle adjustment, loosen the full side stopper bolt (D).
(5)Move the lever (A) in the full speed direction.
(6)Fix bolt (D) at full speed position.
(7)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
----------
----------
----------
----------
Information:
Test Procedure
System Operation
The engine speed switch accepts a signal from the magnetic pickup. The magnetic pickup is mounted on the engine. The speed switch determines the engine speed from the signal. The speed switch provides contacts for the following list of conditions:
Crank Terminate
Engine Oil Step Pressure
Engine Overspeed
Nine Second Time Delay
Illustration 1 g00562933
Diagram of the engine speed switchFunctional Test
Check the electrical connectors and check the wiring.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Check the electrical connectors and check the wiring for damage or bad connections.
Verify that all modules are properly seated.
Verify the status of the LED on the SLC 5/04.The results of the preceding procedure are in the following list:
All of the components are fully installed. All of the components are free of corrosion. All of the components are free of damage. All of the modules are properly seated. Proceed to 2.
The components are not fully installed. The components are not free of corrosion. The components are damaged. All of the modules are not properly seated. Repair the component. Verify that the repair resolves the problem. STOP.
Verify that the engine speed switch is receiving power.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Measure the voltage on the junction box terminal strip. Measure the voltage between the following terminals: junction box terminal 6 and junction box terminal 5. The voltage should be 24 2 VDC between the junction box terminals.The results of the preceding procedure are in the following list:
The voltage is in the range. Proceed to 3.
The voltage is not in the range. Refer to Troubleshooting, "System Power". Stop.
Check the magnetic pickup.
Measure the voltage on the junction box terminal strip. Measure the voltage between the following terminals: junction box terminal 4 and junction box terminal 3. The voltage should be 5 2 VAC between the junction box terminals.The results of the preceding procedure are in the following list:
The voltage is in the range. Proceed to 4.
The voltage is not in the range. Refer to Troubleshooting, "System Power". Stop.
Test the contact for the engine speed switch.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Press the overspeed reset. This de-energizes the contact for the overspeed switch.
Measure the resistance on the junction box terminal strip. Measure the resistance between the following terminals: junction box terminal 11 and junction box terminal 12. The resistance should be zero ohms between the junction box terminals.The results of the preceding procedure are in the following list:
The resistance is good. Stop.
The resistance is not good. Replace the engine speed switch. Stop.
System Operation
The engine speed switch accepts a signal from the magnetic pickup. The magnetic pickup is mounted on the engine. The speed switch determines the engine speed from the signal. The speed switch provides contacts for the following list of conditions:
Crank Terminate
Engine Oil Step Pressure
Engine Overspeed
Nine Second Time Delay
Illustration 1 g00562933
Diagram of the engine speed switchFunctional Test
Check the electrical connectors and check the wiring.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Check the electrical connectors and check the wiring for damage or bad connections.
Verify that all modules are properly seated.
Verify the status of the LED on the SLC 5/04.The results of the preceding procedure are in the following list:
All of the components are fully installed. All of the components are free of corrosion. All of the components are free of damage. All of the modules are properly seated. Proceed to 2.
The components are not fully installed. The components are not free of corrosion. The components are damaged. All of the modules are not properly seated. Repair the component. Verify that the repair resolves the problem. STOP.
Verify that the engine speed switch is receiving power.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Measure the voltage on the junction box terminal strip. Measure the voltage between the following terminals: junction box terminal 6 and junction box terminal 5. The voltage should be 24 2 VDC between the junction box terminals.The results of the preceding procedure are in the following list:
The voltage is in the range. Proceed to 3.
The voltage is not in the range. Refer to Troubleshooting, "System Power". Stop.
Check the magnetic pickup.
Measure the voltage on the junction box terminal strip. Measure the voltage between the following terminals: junction box terminal 4 and junction box terminal 3. The voltage should be 5 2 VAC between the junction box terminals.The results of the preceding procedure are in the following list:
The voltage is in the range. Proceed to 4.
The voltage is not in the range. Refer to Troubleshooting, "System Power". Stop.
Test the contact for the engine speed switch.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Press the overspeed reset. This de-energizes the contact for the overspeed switch.
Measure the resistance on the junction box terminal strip. Measure the resistance between the following terminals: junction box terminal 11 and junction box terminal 12. The resistance should be zero ohms between the junction box terminals.The results of the preceding procedure are in the following list:
The resistance is good. Stop.
The resistance is not good. Replace the engine speed switch. Stop.
Have questions with 101602-0620?
Group cross 101602-0620 ZEXEL
Isuzu
101602-0620
9 400 610 143
1156009241
INJECTION-PUMP ASSEMBLY
6BD1T
6BD1T