Information injection-pump assembly
BOSCH
9 400 615 259
9400615259
ZEXEL
101603-8320
1016038320
ISUZU
8943950500
8943950500
Rating:
Service parts 101603-8320 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94394-787-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101603-8320
as INJECTION-PUMP ASSEMBLY
Include in #2:
104742-1412
as _
Cross reference number
BOSCH
9 400 615 259
9400615259
ZEXEL
101603-8320
1016038320
ISUZU
8943950500
8943950500
Zexel num
Bosch num
Firm num
Name
101603-8320
9 400 615 259
8943950500 ISUZU
INJECTION-PUMP ASSEMBLY
6HE1 * K 14BF INJECTION PUMP ASSY PE6AD PE
6HE1 * 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
4.2
4.15
4.25
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
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
10.9
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
61.5
59.9
63.1
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.
10.5
9.2
11.8
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
900
900
900
Average injection quantity
mm3/st.
61.5
60.5
62.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.1
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
73.5
69.5
77.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.3
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
48.6
45.4
51.8
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
99
99
131
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1210--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1160
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
5.5
5
6
Load
4/4
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.
----------
T1=G22
----------
----------
T1=G22
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=12deg+-5deg b=38deg+-3deg
----------
aa=35mm
----------
a=12deg+-5deg b=38deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=67mm
----------
a=16deg+-5deg b=29deg+-5deg
----------
aa=67mm
----------
a=16deg+-5deg b=29deg+-5deg
0000001501 I/P WITH LOAD PLUNGER ADJ
Plunger assembly number: PL (stamping: ST)
1. Adjustment procedures
(1)Insert the pre-stroke adjusting shims L1 for each cylinder.
(2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2)
(3)At basic point A, adjust so that the pre-stroke is L2.
(4)Reconfirm the injection quantity.
----------
PL=131153-4520 ST=A724 L1=1mm L2=4.2+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131153-4520 ST=A724 L1=1mm L2=4.2+-0.05mm a1=+-14% a2=+-2.5%
----------
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=8deg
----------
a=(150deg)
----------
aa=8deg
----------
a=(150deg)
Information:
1. Remove six bolts (1) and remove the fan.2. Loosen the fan belts and alternator belts. Remove the belts. 3. Remove four bolts (3) and adjusting bolt (2). Remove the fan drive.Install Fan Drive
1. Put the fan drive in position on the engine and install the four bolts.2. Install the adjusting bolt. Install the fan and alternator belts. Make an adjustment to the tension. The correct belt tension is 7/8 in. (22 mm) movement for used belts and 3/4in. (19 mm) movement for new belts when measured with the application of a 25 lb. (11 kg) force half way between the two pulleys.3. Tighten the four fan drive bolts.4. Install the fan with the six bolts.Disassemble Fan Drive
start by: a) remove fan drive 1. Remove two bolts and washers (2). Remove hub (1). 2. Bend down the lock plate and remove bolts (4). Remove the lock plate and washer (3). 3. Use tool (A) to remove the pulley from the bracket assembly. 4. Remove the two bearings and the seal with tool (B).5. Remove the spacer.Assemble Fan Drive
1. Put multipurpose grease on the seal. Install the seal on the pulley with tool (A).2. Install the pulley in the bracket assembly. Fill half the space between the two bearings with multipurpose grease.3. Heat two bearings in oil. The temperature of the oil must be 300° 25°F (149° 14°C).
The bearing heating oil used to heat the bearings must have a flash point above 400°F (204°C).
4. Put multipurpose grease on the bearings. Install the bearing, spacer and bearing with tool (A). 5. Install the washer, lock plate and two bolts. Bend the lock plate up.6. Install the hub with the two bolts and lockwashers.end by: a) install fan drive
1. Put the fan drive in position on the engine and install the four bolts.2. Install the adjusting bolt. Install the fan and alternator belts. Make an adjustment to the tension. The correct belt tension is 7/8 in. (22 mm) movement for used belts and 3/4in. (19 mm) movement for new belts when measured with the application of a 25 lb. (11 kg) force half way between the two pulleys.3. Tighten the four fan drive bolts.4. Install the fan with the six bolts.Disassemble Fan Drive
start by: a) remove fan drive 1. Remove two bolts and washers (2). Remove hub (1). 2. Bend down the lock plate and remove bolts (4). Remove the lock plate and washer (3). 3. Use tool (A) to remove the pulley from the bracket assembly. 4. Remove the two bearings and the seal with tool (B).5. Remove the spacer.Assemble Fan Drive
1. Put multipurpose grease on the seal. Install the seal on the pulley with tool (A).2. Install the pulley in the bracket assembly. Fill half the space between the two bearings with multipurpose grease.3. Heat two bearings in oil. The temperature of the oil must be 300° 25°F (149° 14°C).
The bearing heating oil used to heat the bearings must have a flash point above 400°F (204°C).
4. Put multipurpose grease on the bearings. Install the bearing, spacer and bearing with tool (A). 5. Install the washer, lock plate and two bolts. Bend the lock plate up.6. Install the hub with the two bolts and lockwashers.end by: a) install fan drive
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Group cross 101603-8320 ZEXEL
Isuzu
101603-8320
9 400 615 259
8943950500
INJECTION-PUMP ASSEMBLY
6HE1
6HE1