Information injection-pump assembly
BOSCH
9 400 610 671
9400610671
ZEXEL
101603-8671
1016038671
ISUZU
8943959681
8943959681
Rating:
Service parts 101603-8671 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94395-498-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101603-8671
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-5491
as _
Cross reference number
BOSCH
9 400 610 671
9400610671
ZEXEL
101603-8671
1016038671
ISUZU
8943959681
8943959681
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
105780-8260
Bosch type code
9 430 610 133
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
18
Opening pressure
kgf/cm2
184
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
3.95
4.05
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
11.6
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
91.5
89.9
93.1
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
Z
Rack position
9.6+-0.5
Pump speed
r/min
240
240
240
Average injection quantity
mm3/st.
9.4
8.1
10.7
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(11.6)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
91.5
90.5
92.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.95
Pump speed
r/min
1425
1425
1425
Average injection quantity
mm3/st.
100.5
96.5
104.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.6
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
98.5
94.5
102.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
130
130
138
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
905--
Advance angle
deg.
0
0
0
Load
0/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
855
Advance angle
deg.
0.3
Load
0/4
Timer adjustment_03
Pump speed
r/min
(900)
Advance angle
deg.
0
0
0
Load
4/4
Remarks
Start
Start
Timer adjustment_04
Pump speed
r/min
1425
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.
(3)RACK LIMIT
----------
T1=K97
----------
----------
T1=K97
----------
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=13deg+-5deg b=38deg+-3deg
----------
aa=35mm
----------
a=13deg+-5deg b=38deg+-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
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=7deg
----------
a=(150deg)
----------
aa=7deg
----------
a=(150deg)
Information:
start by: a) remove vibration damper and pulley 1. Use tooling (A) to remove the crankshaft front seal from the timing gear cover. When a replacement of the front seal is made, a replacement of the wear sleeve is to be made also. 2. Put tool (B) in position in the seal bore as shown.3. Install tool (C) between tool (B) and the wear sleeve. Turn tool (C) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose.4. Remove tool (B) and the wear sleeve by hand.5. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 8M8060 Quick Cure Primer. Put 9S3265 Retaining Compound on the crankshaft outside diameter and wear sleeve inside diameter before the wear sleeve is installed on the crankshaft. 6. Put a small amount of clean oil on the lip of the seal. Install wear sleeve (2) and seal (1) on the crankshaft as shown with tools (D). If tools are not available, install the wear sleeve until it is .060 .020 in. (1.52 0.51 mm) (dimension "X") from the face of the crankshaft. Install the seal in the timing gear cover until the metal face of the seal is .090 .020 in. (2.29 0.51 mm) (dimension "Y") from the face of the crankshaft.end by: a) install vibration damper and pulleyRemove And Install Crankshaft Rear Seal And Wear Sleeve
start by:a) remove flywheel 1. Use tool (A) to remove crankshaft rear seal (1) from the flywheel housing. When a replacement of the rear seal is made, a replacement of the wear sleeve is to be made also.
TYPICAL EXAMPLE2. Put tool (B) in position in the seal bore as shown.3. Install tool (C) between tool (B) and the wear sleeve. Turn tool (C) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose.4. Remove tool (B) and the wear sleeve by hand.5. Clean and make a preparation of the wear sleeve inside diameter and adapter outside diameter with 8M8060 Quick Cure Primer. Put 9S3265 Retaining Compound on the adapter outside diameter and wear sleeve inside diameter before the wear sleeve is installed on the adapter. Make sure the lip of the seal is toward the inside of the engine and the outside diameter bevel of the wear sleeve is toward the outside of the engine.6. Put a small amount of clean engine oil on the lip of the seal. Install the wear sleeve and the seal on the crankshaft as shown with tools (D).end by:a) install flywheel
start by:a) remove flywheel 1. Use tool (A) to remove crankshaft rear seal (1) from the flywheel housing. When a replacement of the rear seal is made, a replacement of the wear sleeve is to be made also.
TYPICAL EXAMPLE2. Put tool (B) in position in the seal bore as shown.3. Install tool (C) between tool (B) and the wear sleeve. Turn tool (C) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose.4. Remove tool (B) and the wear sleeve by hand.5. Clean and make a preparation of the wear sleeve inside diameter and adapter outside diameter with 8M8060 Quick Cure Primer. Put 9S3265 Retaining Compound on the adapter outside diameter and wear sleeve inside diameter before the wear sleeve is installed on the adapter. Make sure the lip of the seal is toward the inside of the engine and the outside diameter bevel of the wear sleeve is toward the outside of the engine.6. Put a small amount of clean engine oil on the lip of the seal. Install the wear sleeve and the seal on the crankshaft as shown with tools (D).end by:a) install flywheel