Information injection-pump assembly
BOSCH
9 400 610 669
9400610669
ZEXEL
101603-8651
1016038651
ISUZU
8943959792
8943959792
Rating:
Service parts 101603-8651 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94390-499-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 669
9400610669
ZEXEL
101603-8651
1016038651
ISUZU
8943959792
8943959792
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)
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
4.7
4.65
4.75
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
12.6
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
82
80.4
83.6
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
275
275
275
Average injection quantity
mm3/st.
8.5
7.2
9.8
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(12.6)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
82
81
83
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(12.6)
Pump speed
r/min
1425
1425
1425
Average injection quantity
mm3/st.
88.5
85.3
91.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.2
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
72.5
69.3
75.7
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1300--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1250
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
4.5
4
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.
----------
T1=K49
----------
----------
T1=K49
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=14deg+-5deg b=40deg+-3deg
----------
aa=35mm
----------
a=14deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-5deg b=40deg+-5deg
----------
aa=46.5mm
----------
a=34.5deg+-5deg b=40deg+-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=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131153-9020 ST=A769 L1=1mm L2=4.7+-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)At rack position = bb
----------
aa=6deg bb=R1(12.6)mm
----------
a=(150deg)
----------
aa=6deg bb=R1(12.6)mm
----------
a=(150deg)
Information:
start by:a) remove valve covers and bases Hoods and engine side panels and doors are removed for photo purposes only. 1. Use tool (A) to disconnect the fuel line assemblies from the cylinder head.2. Disconnect fuel line assemblies (1) from the fuel injection valves and remove them from the engine. Install covers on all fuel line connections to keep dirt or foreign material out of the fuel system. 3. Remove nut (2) that holds the fuel injection valve to the adapter assembly. 4. Use tool (B) to remove the fuel injection valves.5. If the fuel injection valves can not be removed with tool (B), use tooling (C). 6. Remove nozzle assembly (3) from body (4).7. Remove seal (5) from the body.Install Fuel Injection Valves
1. Use tool (A) to install seal (2) on valve body (1). 2. Install nozzle assembly (3) on the valve body. Tighten nozzle finger tight only.3. Put a small amount of clean diesel fuel on the seal and install the fuel injection valves in the adapter assemblies.4. Install the nut that holds the fuel injection valves and tighten to a torque of 55 5 lb.ft. (75 7 N m). 5. Remove the covers from the fuel line connections. Put fuel line assemblies (4) in position on the engine. Use tool (B) to tighten the fuel line nuts on the cylinder head adapter assembly. 6. Use tool (C) to tighten fuel line nuts to a torque of 30 5 lb.ft. (40 7 N m).end by:a) install valve covers and bases
1. Use tool (A) to install seal (2) on valve body (1). 2. Install nozzle assembly (3) on the valve body. Tighten nozzle finger tight only.3. Put a small amount of clean diesel fuel on the seal and install the fuel injection valves in the adapter assemblies.4. Install the nut that holds the fuel injection valves and tighten to a torque of 55 5 lb.ft. (75 7 N m). 5. Remove the covers from the fuel line connections. Put fuel line assemblies (4) in position on the engine. Use tool (B) to tighten the fuel line nuts on the cylinder head adapter assembly. 6. Use tool (C) to tighten fuel line nuts to a torque of 30 5 lb.ft. (40 7 N m).end by:a) install valve covers and bases