Information injection-pump assembly
BOSCH
9 400 610 670
9400610670
ZEXEL
101603-8661
1016038661
ISUZU
8943959802
8943959802
Rating:
Service parts 101603-8661 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
9 400 610 670
9400610670
ZEXEL
101603-8661
1016038661
ISUZU
8943959802
8943959802
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%
----------
0000001601 AIR CYLINDER
(a) Air cylinder
(b) Speed lever
(c) Lock nut
1. Air cylinder adjustment procedure
(1)Fix the speed lever (b) at the idle side.
(2)Screw in the air cylinder (a)
(3)Set the clearance between the speed lever (b) and the air cylinder (a) to approximately L1.
----------
L1=1mm
----------
----------
L1=1mm
----------
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 oil pump1. Check the connecting rods and caps for their identification and location.2. Turn crankshaft until connecting rod caps are in position shown. 3. Remove the nuts (1) and the cap from connecting rod. Remove lower half of bearing from cap.4. Push the connecting rod away from the crankshaft. Remove the upper half of bearing from connecting rod. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.5. Install upper half of bearing in connecting rod.6. Pull the connecting rod slowly on to the crankshaft.7. Install lower half of bearing in cap. Be sure the tabs in back of bearings are in the tab grooves of connecting rod and cap.
Do not use an impact wrench to tighten the bolts the additional 120° 5°.
8. Use Plastigage (A) to check bearing clearance.9. Put Plastigage (A) on the bearing.10. Put clean engine oil on threads of rod bolts and seat surfaces of nuts. Be sure the cylinder numbers on the rod cap and rod are the same and are on the same side of the connecting rod. Numbers are on the same side of rod and caps as are the grooves for the bearing tabs. If new rods are installed, put the cylinder number on the rod and cap. Do not turn the crankshaft when Plastigage (A) is in position. 11. Install the rod caps (2). Install the nuts. Tighten each nut to a torque of 60 6 lb. ft. (80 8 N m). Put a mark on the nuts and cap and tighten nuts an extra 120° 5° from the mark. Remove the rod cap. Remove Plastigage (A) and check the bearing clearance. The bearing clearance must be .0028 to .0066 in. (0.071 to 0.168 mm) for new bearings. Maximum clearance with used bearings is .010 in. (0.25 mm).12. Put clean engine oil on lower half of bearing. Install rod cap again. Tighten each nut to 60 6 lb.ft. (80 8 N m). Put a mark on nuts and cap and tighten nuts an extra 120° 5° from mark.13. Do Steps 1 through 12 for remainder of connecting rod bearings.end by:a) install oil pump
Do not use an impact wrench to tighten the bolts the additional 120° 5°.
8. Use Plastigage (A) to check bearing clearance.9. Put Plastigage (A) on the bearing.10. Put clean engine oil on threads of rod bolts and seat surfaces of nuts. Be sure the cylinder numbers on the rod cap and rod are the same and are on the same side of the connecting rod. Numbers are on the same side of rod and caps as are the grooves for the bearing tabs. If new rods are installed, put the cylinder number on the rod and cap. Do not turn the crankshaft when Plastigage (A) is in position. 11. Install the rod caps (2). Install the nuts. Tighten each nut to a torque of 60 6 lb. ft. (80 8 N m). Put a mark on the nuts and cap and tighten nuts an extra 120° 5° from the mark. Remove the rod cap. Remove Plastigage (A) and check the bearing clearance. The bearing clearance must be .0028 to .0066 in. (0.071 to 0.168 mm) for new bearings. Maximum clearance with used bearings is .010 in. (0.25 mm).12. Put clean engine oil on lower half of bearing. Install rod cap again. Tighten each nut to 60 6 lb.ft. (80 8 N m). Put a mark on nuts and cap and tighten nuts an extra 120° 5° from mark.13. Do Steps 1 through 12 for remainder of connecting rod bearings.end by:a) install oil pump