Information injection-pump assembly
BOSCH
9 400 615 258
9400615258
ZEXEL
101603-8310
1016038310
ISUZU
1156022900
1156022900
Rating:
Service parts 101603-8310 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-251-1
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
101603-8310
as INJECTION-PUMP ASSEMBLY
Include in #2:
104742-1402
as _
Cross reference number
BOSCH
9 400 615 258
9400615258
ZEXEL
101603-8310
1016038310
ISUZU
1156022900
1156022900
Zexel num
Bosch num
Firm num
Name
101603-8310
9 400 615 258
1156022900 ISUZU
INJECTION-PUMP ASSEMBLY
6SA1-T K 14BF INJECTION PUMP ASSY PE6AD PE
6SA1-T K 14BF INJECTION PUMP ASSY PE6AD 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
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.7
3.65
3.75
Beginning of injection position
Governor side NO.1
Governor 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
12.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
109.5
107.9
111.1
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
290
290
290
Average injection quantity
mm3/st.
9.9
7.9
11.9
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(12.6)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
109.5
108.5
110.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
81.3
81.3
Boost pressure
mmHg
610
610
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.45
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
103.5
100.3
106.7
Fixing the lever
*
Boost pressure
kPa
81.3
81.3
Boost pressure
mmHg
610
610
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.95
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
87
83
91
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
98
98
108
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
900
900
900
Rack position
R1-0.95
Boost pressure
kPa
45.3
44
46.6
Boost pressure
mmHg
340
330
350
Boost compensator adjustment_02
Pump speed
r/min
900
900
900
Rack position
R1(12.6)
Boost pressure
kPa
68
61.3
74.7
Boost pressure
mmHg
510
460
560
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1250
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Boost compensator stroke: BCL
----------
T1=J22 BCL=0.95+-0.1mm
----------
----------
T1=J22 BCL=0.95+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35.5mm
----------
a=18deg+-5deg b=35deg+-3deg
----------
aa=35.5mm
----------
a=18deg+-5deg b=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=45mm
----------
a=25deg+-5deg b=40deg+-5deg
----------
aa=45mm
----------
a=25deg+-5deg b=40deg+-5deg
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=15deg
----------
a=(40deg)
----------
aa=15deg
----------
a=(40deg)
Information:
2. Remove bolts (1).3. Remove the water hose from the bottom of the water pump.4. Loosen the water hose clamps from water pipe (2).5. Remove two bolts (3) and remove the water pump and elbow as a unit.Install Water Pump
1. Inspect all O-rings, gaskets and hoses and install new parts if needed.2. Put the water pump and elbow in position and install the bolts.3. Install the water hose and tighten all water hose clamps.4. Fill the cooling system to the correct level.Disassemble Water Pump
start by:a) remove water pump1. Remove cover (3) and gasket from water pump (1).2. Remove elbow (2) and gasket from water pump (1). 3. Loosen bolt (5) .25 in. (6.35 mm). Hit (tap) the bolt with a soft hammer to remove impeller (4) from the shaft. 4. Remove spring and seal assembly (7) from shaft (6). 5. Turn the water pump over and remove bolt (8) and lockwasher.6. Remove O-ring seal (9) from the housing. 7. Use tooling (A) to remove gear (11) and bearing (10) from the water pump.8. Remove bearing (10) from gear (11). 9. Remove snap ring (12) with tool (B). 10. Remove bearing (14) and shaft (13) as a unit.11. Use tool (C) and a press to remove bearing (14) from the shaft. 12. Remove the ceramic ring and seal (15) from the housing. 13. Remove the lip type seal (16) from the housing with tooling (D).Assemble Water Pump
The seal must be installed with the lip toward the bearings.1. Install the lip type seal in housing (1) with tooling (A) to the bottom of the seal counterbore. Put a thin layer of engine oil on the lip of the seal. 2. Use a press to install shaft (2) in bearing (3). 3. Install the shaft and bearing (3) in housing (1). 4. Install snap ring (4) in the housing with tool (B). 5. Install bearing (5) on gear (6).
When gear (6) is installed, make sure the pins on the gear engage the holes in the shaft.
6. Put gear (6) and bearing in position on the shaft and install washer and bolt. 7. Install O-ring seal (7) on the housing.
Clean water only is permitted for use as a lubricant to make assembly easier. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
8. Put the ceramic ring (8) in position in the rubber seal. Use hand pressure and tool (which is with the replacement ring) to install the ceramic ring and rubber seal. 9. Remove the spring from the seal assembly (9). Use hand pressure and the tool (which is with the replacement ring) to install the seal assembly. Push seal assembly on the shaft until seal faces make light contact. 10. Install spring (10) on the seal assembly. 11. Put impeller (11) in position on the shaft. 12. Install washer and bolt (12). Tighten the bolt to
1. Inspect all O-rings, gaskets and hoses and install new parts if needed.2. Put the water pump and elbow in position and install the bolts.3. Install the water hose and tighten all water hose clamps.4. Fill the cooling system to the correct level.Disassemble Water Pump
start by:a) remove water pump1. Remove cover (3) and gasket from water pump (1).2. Remove elbow (2) and gasket from water pump (1). 3. Loosen bolt (5) .25 in. (6.35 mm). Hit (tap) the bolt with a soft hammer to remove impeller (4) from the shaft. 4. Remove spring and seal assembly (7) from shaft (6). 5. Turn the water pump over and remove bolt (8) and lockwasher.6. Remove O-ring seal (9) from the housing. 7. Use tooling (A) to remove gear (11) and bearing (10) from the water pump.8. Remove bearing (10) from gear (11). 9. Remove snap ring (12) with tool (B). 10. Remove bearing (14) and shaft (13) as a unit.11. Use tool (C) and a press to remove bearing (14) from the shaft. 12. Remove the ceramic ring and seal (15) from the housing. 13. Remove the lip type seal (16) from the housing with tooling (D).Assemble Water Pump
The seal must be installed with the lip toward the bearings.1. Install the lip type seal in housing (1) with tooling (A) to the bottom of the seal counterbore. Put a thin layer of engine oil on the lip of the seal. 2. Use a press to install shaft (2) in bearing (3). 3. Install the shaft and bearing (3) in housing (1). 4. Install snap ring (4) in the housing with tool (B). 5. Install bearing (5) on gear (6).
When gear (6) is installed, make sure the pins on the gear engage the holes in the shaft.
6. Put gear (6) and bearing in position on the shaft and install washer and bolt. 7. Install O-ring seal (7) on the housing.
Clean water only is permitted for use as a lubricant to make assembly easier. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
8. Put the ceramic ring (8) in position in the rubber seal. Use hand pressure and tool (which is with the replacement ring) to install the ceramic ring and rubber seal. 9. Remove the spring from the seal assembly (9). Use hand pressure and the tool (which is with the replacement ring) to install the seal assembly. Push seal assembly on the shaft until seal faces make light contact. 10. Install spring (10) on the seal assembly. 11. Put impeller (11) in position on the shaft. 12. Install washer and bolt (12). Tighten the bolt to
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Group cross 101603-8310 ZEXEL
Isuzu
101603-8310
9 400 615 258
1156022900
INJECTION-PUMP ASSEMBLY
6SA1-T
6SA1-T