101401-1011 ZEXEL 9 400 613 595 BOSCH INJECTION-PUMP ASSEMBLY 9400613595 1014011011 ez40086

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 595 9400613595

ZEXEL 101401-1011 1014011011

M.BISHI-HI.-NAG EZ40086 ez40086

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Service parts 101401-1011 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8331

3. GOVERNOR 105410-7240

4. SUPPLY PUMP 105220-4961

5. AUTOM. ADVANCE MECHANIS 105643-5021

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5112

11. Nozzle and Holder EZ41059

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105031-3820

14. NOZZLE 105015-4710

15. NOZZLE SET

Include in #1:

101401-1011 as INJECTION-PUMP ASSEMBLY

106873-3352 as _

106873-3353

Cross reference number

BOSCH 9 400 613 595 9400613595

ZEXEL 101401-1011 1014011011

M.BISHI-HI.-NAG EZ40086 ez40086

Zexel num

Bosch num

Firm num

Name

101401-1011

9 400 613 595

EZ40086 M.BISHI-HI.-NAG

INJECTION-PUMP ASSEMBLY
4AAC * 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

Overflow valve 131424-3720

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

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 4.2 4.15 4.25

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 11.5

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 101.7 100.2 103.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 5.3+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 12.4 10.9 13.9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 14.4+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 149.5 149.5 159.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 2 1.5 2.5

Timer adjustment_03

Pump speed r/min 1150

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=16deg+-5deg b=28deg+-5deg c=32deg+-3deg

Stop lever angle

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

----------
a=43deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark '2' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(90deg)

Information:

Oil Pump
Disassembly and Inspection of Oil Pump
Measurement of Clearance Between Outer Rotor and Inner Rotor
Measure the clearance between the outer rotor and inner rotor, and, if the limit value is exceeded, replace the pump assembly.
Measurement of clearance between outer rotor and inner rotorMeasurement of Rotor and Case End Play
Measure the rotor and case end play, and, if the limit value is exceeded, replace the pump assembly.
Measurement of rotor and cover end playMeasurement of Clearance Between Outer Rotor and Pump Case
Measure the clearance between the outer rotor and pump case, and, if the limit value is exceeded, replace the pump assembly.
Measure the clearance between the outer rotor and caseReassembly of Oil Pump
Install the outer rotor to the pump case, check alignment mark (indentations) on the pump case cover, and then tighten the bolts. If the alignment marks are not aligned during the reassembly, the pump will not suck oil.
Alignment marks on pump case and pump case coverOil Filter and Oil Cooler
Disassembly and Inspection of Oil Filter and Oil Cooler
Relief Valve
Inspection of Relief Valve
(1) Check the relief valve and valve seat for contact condition, and the spring for fatigue and damage, and replace any defective parts.(2) Measure the valve opening pressure (oil pressure when the engine is running at rated rpm) of the relief valve, and, if the standard valve is exceeded, remove the cap bolt and make an adjustment by increasing or decreasing the shim thickness.
Relief Valve