Information injection-pump assembly
BOSCH
9 400 611 899
9400611899
ZEXEL
106671-6450
1066716450
ISUZU
1156033340
1156033340
Rating:
Service parts 106671-6450 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-389-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}/22.1{225}
14.
NOZZLE
Include in #1:
106671-6450
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 899
9400611899
ZEXEL
106671-6450
1066716450
ISUZU
1156033340
1156033340
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)
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
2.9
2.87
2.93
Beginning of injection position
Governor side NO.1
Governor 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
12.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
133.5
132.5
134.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
160
160
Boost pressure
mmHg
1200
1200
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.5+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
9.5
6.3
12.7
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
E
Rack position
13++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
155
145
165
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
10.5
Boost pressure
kPa
48
44
52
Boost pressure
mmHg
360
330
390
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
11.2
Boost pressure
kPa
147
140.3
153.7
Boost pressure
mmHg
1100
1050
1150
Timer adjustment
Pump speed
r/min
1200++
Advance angle
deg.
0
0
0
Remarks
Do not advance until starting N = 1200.
Do not advance until starting N = 1200.
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)Boost compensator stroke: BCL
(5)Main spring setting
(6)Set idle sub-spring
----------
K=10 BCL=0.7+-0.1mm
----------
----------
K=10 BCL=0.7+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Use the hole at R = aa
----------
aa=70mm
----------
a=3deg+-5deg b=18deg+-5deg c=31deg+-3deg
----------
aa=70mm
----------
a=3deg+-5deg b=18deg+-5deg c=31deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Use the hole at R = aa
(3)Rack position bb, pump speed cc (seal at delivery)
----------
aa=23mm bb=1-0.5mm cc=0r/min
----------
a=15deg+-5deg b=70deg+-5deg
----------
aa=23mm bb=1-0.5mm cc=0r/min
----------
a=15deg+-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=9deg
----------
a=(50deg)
----------
aa=9deg
----------
a=(50deg)
Information:
Illustration 1 g00564355
7W-2743 Electronic Speed Switch (ESS)
(1) Push button for Overspeed Verification
(2) Reset button
(3) Overspeed indicator lamp
(4) Seal screw plug for adjusting the engine overspeed
(5) Seal screw plug for adjusting the crank terminate speed
(6) Seal screw plug for adjusting the oil step pressure speed setting The calibration of the crank terminate adjustment can increase the crank terminate speed or the calibration of the crank terminate adjustment can decrease the crank terminate speed. The crank terminate speed determines when the starting motor is disengaged. The starting motor is disengaged when the system voltage is cancelled by the crank termination speed. At the crank terminate speed, the engine must be able to run without the assistance of the starting motor.
Remove the lockwire and the seal from seal screw plug (5). Remove seal screw plug (5) from the access hole for the crank terminate adjusting screw.
Use a small screwdriver to lightly turn the crank terminate adjusting screw in the direction of the "MAX" arrow or the clockwise direction. Turn the screw twenty times. The crank terminate adjusting screw will vary the setting of a potentiometer that is inside of the ESS. The crank terminate adjusting screw will not cause damage to the potentiometer. Also, the screw can not be removed if the screw is turned in the wrong direction.
Turn the crank terminate adjusting screw for twelve turns in the opposite direction of the "MAX" arrow or the counterclockwise direction. This will establish an approximate crank terminate setting.
Connect a voltmeter with the positive lead at terminal (ESS-12) and the negative lead at (ESS-5). Use a 6V-7070 Digital Multimeter or a voltmeter with the same accuracy. Start the engine. Record the engine rpm when the starting motor disengages. The starting motor disengages when the open circuit voltage is cancelled by the crank terminate setting. Refer to the Speed Specification Chart for the correct crank terminate setting.
If the setting in Step 4 is not correct, proceed with Steps 6, 7, and 8. If the setting is correct go to Step 8.
Stop the engine and turn the crank terminate adjusting screw for one full turn in the clockwise direction in order to increase the crank terminate speed. Turn the crank terminate adjusting screw for one full turn in the counterclockwise direction in order to decrease the crank terminate speed.
While the voltmeter is still connected, start the engine. Record the engine rpm when the starting motor disengages. The starting motor will disengage when the voltage is cancelled by the crank terminate speed. Repeat Steps 6 and 7 until the crank terminate speed is correct.
Install seal screw plug (5) in the access hole for the crank terminate adjusting screw. Tighten the screw to a torque of 0.20 0.03 N m (1.8 .3 lb in). Install the lockwire and the seal if the overspeed calibration and the oil step speed calibration are also complete.