Information injection-pump assembly
BOSCH
9 400 619 551
9400619551
ZEXEL
101603-4460
1016034460
ISUZU
1156022212
1156022212
Rating:
Service parts 101603-4460 INJECTION-PUMP ASSEMBLY:
1.
_
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
9 400 619 551
9400619551
ZEXEL
101603-4460
1016034460
ISUZU
1156022212
1156022212
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 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
3.6
3.55
3.65
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
-
Rack position
10.9
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
60.3
58.7
61.9
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
8.7
7.4
10
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.9)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
60.3
59.3
61.3
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
C
Rack position
R1-0.05
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
64
62.4
65.6
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
D
Rack position
R1(10.9)
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
46.9
45.3
48.5
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1050--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1000
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1300
Advance angle
deg.
1.8
1.3
2.3
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
3.2
2.7
3.7
Timer adjustment_05
Pump speed
r/min
-
Advance angle
deg.
4
4
4
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT: RAL
----------
T1=19 RAL=13.6+0.2mm
----------
----------
T1=19 RAL=13.6+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=35mm
----------
a=39deg+-5deg b=36deg+-3deg
----------
aa=35mm
----------
a=39deg+-5deg b=36deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
0000001501 TAMPER PROOF
Tamper proof adjustment
(1)Set the full load screw at rack position Ra+0.4.
(2)Set the full load position Ra using screw (A).
----------
Ra=R1(10.9)+0.4mm
----------
----------
Ra=R1(10.9)+0.4mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(60deg)
----------
aa=14deg
----------
a=(60deg)
Information:
941B 80H3884-Up
(1) Remove the engine from the machine; see the Service Manual for the procedure. Put both engines, new and old, in a position that will give good access to their front, rear, top and both sides. For those engines that were equipped with glow plugs, either remove the wire from the heat-start switch to the glow plug lead assembly, or put tape over the end of the wire when it is disconnected. This wire will not be needed because the new engine does not have glow plugs.(2) From the old engine, remove the crankshaft pulley and hub, engine front support, the rear supports (from the sides of the flywheel housing) and the flywheel. Install these
(1) Remove the engine from the machine; see the Service Manual for the procedure. Put both engines, new and old, in a position that will give good access to their front, rear, top and both sides. For those engines that were equipped with glow plugs, either remove the wire from the heat-start switch to the glow plug lead assembly, or put tape over the end of the wire when it is disconnected. This wire will not be needed because the new engine does not have glow plugs.(2) From the old engine, remove the crankshaft pulley and hub, engine front support, the rear supports (from the sides of the flywheel housing) and the flywheel. Install these