104303-3430 ZEXEL 9 400 616 471 BOSCH INJECTION-PUMP ASSEMBLY 9400616471 1043033430 51215101000

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 471 9400616471

ZEXEL 104303-3430 1043033430

TOYO-SHA 51215101000 51215101000

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Service parts 104303-3430 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 104300-6130

3. GOVERNOR

4. SUPPLY PUMP

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-1900

11. Nozzle and Holder 2251-1210-01

12. Open Pre:MPa(Kqf/cm2) 12.7{130}

13. NOZZLE-HOLDER 105071-0570

14. NOZZLE

105000-1650

15. NOZZLE SET

Include in #1:

104303-3430 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 471 9400616471

ZEXEL 104303-3430 1043033430

TOYO-SHA 51215101000 51215101000

Zexel num

Bosch num

Firm num

Name

104303-3430

9 400 616 471

51215101000 TOYO-SHA

INJECTION-PUMP ASSEMBLY
3S221 * K

Calibration Data:

Adjustment conditions

Test oil
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

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-2

Pre-stroke mm 2.2 2.15 2.25

Rack position
After adjusting injection quantity. R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 2
Cyl.1-2 deg. 240 239.5 240.5

Injection quantity adjustment

Adjusting point A

Rack position 10.5

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 43.3 42.3 44.3

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 45.4 43.4 47.4

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.9+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 11 10 12

Max. variation between cylinders % 0 -14 14

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Set the idle spring. (2)Main spring setting (3)Rack difference between N = N1 and N = N2
----------
N1=1250r/min N2=800r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=16deg+-3deg b=31deg+-6deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=18deg+-3deg b=(38deg)

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (at full load) (3)- (4)-
----------

----------
a=(40deg)

Information:

1. Remove oil supply tube (1) and suction bell and tube (2). 2. Remove bolts (3) that hold the oil pump to the cylinder block and remove oil pump (4).3. To install, put oil pump (4) in position on the cylinder block. Install the bolts that hold the oil pump to the cylinder block.4. Put clean engine oil on the O-ring seals of the tubes.5. Install oil supply tube (1), suction bell and tube (2).End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump 1. Remove the bolt and washer that hold the gear on the shaft.2. Use Tool (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve. Remove the spring and the bypass valve.4. Remove cover (2) from the pump body. 5. Use Tool (B) and remove the bearings from the cover. 6. Remove gears (5) from pump body (4).7. Use Tool (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use Tool (B) to install the bearings in the pump body. Install the bearings so the joint in the bearings is 30 15 degrees from the center line of the oil pump outlet passage (2). 2. Install idler gear and drive gear (5) in the oil pump body (4). Put clean engine oil on the bearings and the gears. 3. Use Tool (A) and install the bearings in cover (2). Install the bearings so the joint of the bearing bores toward oil pump outlet passage (6).4. Install bypass valve (7), spring (8) and the retainer.5. Install the key on the shaft. 6. Install gear (1) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.End By:a. install oil pump