Rating:
Information injection-pump assembly
BOSCH
9 400 619 006
9400619006
ZEXEL
107692-1180
1076921180
ISUZU
1156029460
1156029460
Service parts 107692-1180 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
1-15300-274-6
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
107692-1180
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 006
9400619006
ZEXEL
107692-1180
1076921180
ISUZU
1156029460
1156029460
Zexel num
Bosch num
Firm num
Name
107692-1180
9 400 619 006
1156029460 ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-TC2 K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS
6BG1-TC2 K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS
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
131425-0520
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
PS/ACT control unit part no.
407910-3
03*
Selector switch no.
00
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
11
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
2.3
2.27
2.33
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
-
Rack position
12.5
Pump speed
r/min
975
975
975
Average injection quantity
mm3/st.
95.5
93.9
97.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
PS407980-224*
V
1.88+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
1.88+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8.1+-0.5
Pump speed
r/min
660
660
660
Average injection quantity
mm3/st.
12.5
11.2
13.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
PS407980-224*
V
1.88+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
1.88+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.5)
Pump speed
r/min
975
975
975
Average injection quantity
mm3/st.
95.5
94.5
96.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
53.3
53.3
Boost pressure
mmHg
400
400
PS407980-224*
V
1.88+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
1.88+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R2-1.9
Boost pressure
kPa
10.7
10.7
10.7
Boost pressure
mmHg
80
80
80
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R2-0.8
Boost pressure
kPa
26.7
25.4
28
Boost pressure
mmHg
200
190
210
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
R2(R1-0.
95)
Boost pressure
kPa
40
33.3
46.7
Boost pressure
mmHg
300
250
350
0000001601
CU407980-224*
*
Actuator advancing type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.4
5.35
5.45
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_02
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.3
2.27
2.33
Output voltage
V
1.2
1
1.4
Confirmation
*
_03
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
_04
CU407910-303*
*
Actuator advancing type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.4
5.35
5.45
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_05
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.3
2.27
2.33
Output voltage
V
1.2
1
1.4
Confirmation
*
_06
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
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)Boost compensator stroke: BCL
----------
T1=G46 BCL=1.9+-0.1mm
----------
----------
T1=G46 BCL=1.9+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt setting
----------
aa=35mm
----------
a=43deg+-5deg b=40deg+-3deg
----------
aa=35mm
----------
a=43deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)-
(2)Set the stopper bolt at speed = aa and rack position = bb and confirm non-injection.
----------
aa=1400r/min bb=5-0.5mm
----------
a=20deg+-5deg b=37deg+-5deg
----------
aa=1400r/min bb=5-0.5mm
----------
a=20deg+-5deg b=37deg+-5deg
0000001301
(1)Pump vertical direction
(2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=2.3+-0.03mm
----------
a=(140deg)
----------
aa=2.3+-0.03mm
----------
a=(140deg)
0000001401
(1)Pointer
(2)Injection timing aligning mark
(3)Fly weight
(4)The actual shape and direction may be different from this illustration.
Operation sequence
1. Turn the prestroke actuator OFF.
2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position.
3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching.
4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark.
5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------
----------
----------
----------
0000001701
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001801
C:Shim
----------
----------
----------
----------
0000001901
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the counterclockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000002201 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1400r/min Ra=R3(R1+1.4)mm
----------
----------
N1=1400r/min Ra=R3(R1+1.4)mm
----------
0000002301 ACS
(A) Aneroid compensator
(B) Set screw
(C) Boost pressure inlet
(D) Rack positioning screw
(E): Aneroid compensator main body
(F) Boost compensator spring
(G): Aneroid compensator spring
(H): Adjusting notch
(I) Push rod
1. Instructions for adjusting the boost compensator with the aneroid compensator
(1)Select a pushrod to obtain L1 at full boost.
(2)Remove the aneroid compensator main body.
(3)Adjust the booster compensator stroke by turning the screw at (D.
(4)Adjust the beginning of boost compensator operation by turning the notch at (H).
(5)Install the aneroid compensator at full boost state.
(6)Turn (B)'s set screw so that the distance between the snapring and the body is L2.
(7)Screw in the aneroid compensator main body and adjust the point where it comes into play.
----------
L1=24+-0.5mm L2=1.5+-0.5mm
----------
----------
L1=24+-0.5mm L2=1.5+-0.5mm
----------
0000002401 ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
1. Adjustment of the aneroid compensator itself and the adjustment after mounting the governor
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Screw in (A) to obtain the performance shown in the graph (to obtain L1).
(3)Adjust the (D) spacer so that dimension L2 is obtained.
(4)As there is hysterisis, measure when the absolute pressure drops.
(5)Hysterisis must not exceed rack position = h1.
----------
N1=975r/min L1=1.5+-0.5mm L2=24+-0.5mm h1=0.15mm
----------
Ra=R1(12.5)mm Rb=R4(R1-0.3)mm P1=(80)+-2.7kPa((600)+-20mmHg) P2=70.1+-0.7kPa(526+-5mmHg) Q1=95.5+-1cm3/1000st Q2=88.8+-2cm3/1000st
----------
N1=975r/min L1=1.5+-0.5mm L2=24+-0.5mm h1=0.15mm
----------
Ra=R1(12.5)mm Rb=R4(R1-0.3)mm P1=(80)+-2.7kPa((600)+-20mmHg) P2=70.1+-0.7kPa(526+-5mmHg) Q1=95.5+-1cm3/1000st Q2=88.8+-2cm3/1000st
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107692-1180
9 400 619 006
1156029460
INJECTION-PUMP ASSEMBLY
6BG1-TC2
6BG1-TC2