Information injection-pump assembly
BOSCH
9 400 611 951
9400611951
ZEXEL
106671-6440
1066716440
ISUZU
1156033410
1156033410
Rating:
Service parts 106671-6440 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-391-0
12.
Open Pre:MPa(Kqf/cm2)
20.1{205}
15.
NOZZLE SET
Include in #1:
106671-6440
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 951
9400611951
ZEXEL
106671-6440
1066716440
ISUZU
1156033410
1156033410
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-4320
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.9
3.87
3.93
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
11.9
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
216
214
218
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
128
128
Boost pressure
mmHg
960
960
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.6+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
8
4.8
11.2
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
E
Rack position
12.9++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
310
300
320
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-0.8
Boost pressure
kPa
77.3
73.3
81.3
Boost pressure
mmHg
580
550
610
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(11.9)
Boost pressure
kPa
115
108.3
121.7
Boost pressure
mmHg
860
810
910
Timer adjustment
Pump speed
r/min
1000++
Advance angle
deg.
0
0
0
Remarks
Do not advance until starting N = 1000.
Do not advance until starting N = 1000.
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
0.7
0.7
0.7
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Boost compensator stroke: BCL
(6)Main spring setting
----------
K=8 BCL=0.8+-0.1mm
----------
----------
K=8 BCL=0.8+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Use the hole at R = aa
----------
aa=70mm
----------
a=20deg+-5deg b=13deg+-3deg c=18deg+-5deg
----------
aa=70mm
----------
a=20deg+-5deg b=13deg+-3deg c=18deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Rack position = aa, speed = bb (stamp at delivery)
(3)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=23mm
----------
a=53deg+-5deg b=70deg+-5deg
----------
aa=1-0.5mm bb=0r/min cc=23mm
----------
a=53deg+-5deg b=70deg+-5deg
0000001501 TAMPER PROOF
Tamperproofing-equipped boost compensator cover installation procedure
(A) After adjusting the boost compensator, tighten the bolts to remove the heads.
(1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
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=11deg
----------
a=(100deg)
----------
aa=11deg
----------
a=(100deg)
Information:
Problem 4
The starting motor remains engaged or the starting motor continues to run after the engine is running.
Check the components of the starting circuit.
Measure the voltages at terminal (TS-26) of the junction box while the engine is running.Result
The voltage at the terminal is zero volts.The problem is in the starting motor (SM), the pinion solenoid (PS), or the magnetic switch (MS). Repair the faulty component. STOP.
The voltage at the terminal is between 15 volts and 32 volts.The START terminals of the start/stop switch are normally closed. This is normal for an automatic start system. In a manual start system, the switches should be normally open. The switch is on terminals (SSS-1) and (SSS-2) for a normal start/stop switch. Repair the faulty switch. STOP.Problem 5
The engine shutdown occurs after the engine runs for more than 3 minutes.
Check the protection switches.
Remove the jumper that is between terminals (TS-9) and (TS-10) of the junction box.
If the engine is equipped with a low oil pressure indicator, disconnect the diode that is between terminals (TS-8) and (TS-10). The cathode lead of the diode should be connected to terminal (TS-10).
If the engine is equipped with a low oil pressure indicator, ensure that a jumper is not installed between terminals (TS-8) and (TS-9).
Start the engine.
Reconnect the jumper that is between terminals (TS-9) and (TS-10) of the junction box after the test is completed.Result
The engine starts and the engine runs.The problem is in the oil pressure switch or the water temperature contactor switch. Go to Step 5 of "Problem 1".
The engine starts but engine shutdown occurs immediately.Go to Step 1 of "Problem 3".
The engine starts and the engine runs but engine shutdown occurs after the engine runs for more than 3 minutes.Go to Step 2.
The engine cranks but the engine does not start.Go to Step 1 of "Problem 1".
Check the start/stop switch and slave relay (SR1).
Disconnect the wire in the junction box that connects terminal (SR1-85) of the slave relay (SR1) to terminal (TD-7) of the time delay relay (TD).
Crank the engine. Activate the emergency stop switch, if necessary.Result
The engine starts and the engine runs.The start/stop switch has a short circuit or a wiring problem is causing a voltage at terminal (TD-7). Reconnect the wire to the terminal. STOP.
Engine shutdown still occurs after several minutes.The contacts of (SR1) periodically close. The problem may also be with the governor or the fuel supply to the engine. Refer to the Engine Service Manual. If a 2301A Electric Governor is used, the SR1 contacts may be opening. Refer to 2301A Electric Governor Service Manual, SENR3585. Test SR1. Refer to Testing and Adjusting, "Slave Relay Test".Problem 6
Engine shutdown does not occur when a fault is detected.
Check the protection switches and the crank terminate switch of the electronic speed switch.
Reset circuit breaker (CB7).
Start the engine and run the engine at low idle.
Contact with electrical components can cause injury or death.Remove all jewelry and avoid contact with electrical components. Use properly insulated tools when working on the junction box of an
The starting motor remains engaged or the starting motor continues to run after the engine is running.
Check the components of the starting circuit.
Measure the voltages at terminal (TS-26) of the junction box while the engine is running.Result
The voltage at the terminal is zero volts.The problem is in the starting motor (SM), the pinion solenoid (PS), or the magnetic switch (MS). Repair the faulty component. STOP.
The voltage at the terminal is between 15 volts and 32 volts.The START terminals of the start/stop switch are normally closed. This is normal for an automatic start system. In a manual start system, the switches should be normally open. The switch is on terminals (SSS-1) and (SSS-2) for a normal start/stop switch. Repair the faulty switch. STOP.Problem 5
The engine shutdown occurs after the engine runs for more than 3 minutes.
Check the protection switches.
Remove the jumper that is between terminals (TS-9) and (TS-10) of the junction box.
If the engine is equipped with a low oil pressure indicator, disconnect the diode that is between terminals (TS-8) and (TS-10). The cathode lead of the diode should be connected to terminal (TS-10).
If the engine is equipped with a low oil pressure indicator, ensure that a jumper is not installed between terminals (TS-8) and (TS-9).
Start the engine.
Reconnect the jumper that is between terminals (TS-9) and (TS-10) of the junction box after the test is completed.Result
The engine starts and the engine runs.The problem is in the oil pressure switch or the water temperature contactor switch. Go to Step 5 of "Problem 1".
The engine starts but engine shutdown occurs immediately.Go to Step 1 of "Problem 3".
The engine starts and the engine runs but engine shutdown occurs after the engine runs for more than 3 minutes.Go to Step 2.
The engine cranks but the engine does not start.Go to Step 1 of "Problem 1".
Check the start/stop switch and slave relay (SR1).
Disconnect the wire in the junction box that connects terminal (SR1-85) of the slave relay (SR1) to terminal (TD-7) of the time delay relay (TD).
Crank the engine. Activate the emergency stop switch, if necessary.Result
The engine starts and the engine runs.The start/stop switch has a short circuit or a wiring problem is causing a voltage at terminal (TD-7). Reconnect the wire to the terminal. STOP.
Engine shutdown still occurs after several minutes.The contacts of (SR1) periodically close. The problem may also be with the governor or the fuel supply to the engine. Refer to the Engine Service Manual. If a 2301A Electric Governor is used, the SR1 contacts may be opening. Refer to 2301A Electric Governor Service Manual, SENR3585. Test SR1. Refer to Testing and Adjusting, "Slave Relay Test".Problem 6
Engine shutdown does not occur when a fault is detected.
Check the protection switches and the crank terminate switch of the electronic speed switch.
Reset circuit breaker (CB7).
Start the engine and run the engine at low idle.
Contact with electrical components can cause injury or death.Remove all jewelry and avoid contact with electrical components. Use properly insulated tools when working on the junction box of an