Information injection-pump assembly
BOSCH
9 400 612 098
9400612098
ZEXEL
101401-1890
1014011890
Rating:
Service parts 101401-1890 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME016655
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 612 098
9400612098
ZEXEL
101401-1890
1014011890
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 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-4620
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
1-3-4-2
Pre-stroke
mm
3.5
3.45
3.55
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.3
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
90.5
89.5
91.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.8+-0.5
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
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
C
Rack position
10.7++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
55
55
60
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
0
Advance angle
deg.
2.5
2
3
Timer adjustment_02
Pump speed
r/min
(630)
Advance angle
deg.
2.5
2
3
Remarks
Start
Start
Timer adjustment_03
Pump speed
r/min
720+-25
Advance angle
deg.
0
0
0
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Main spring setting
(5)Set idle sub-spring
----------
K=11
----------
----------
K=11
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(6deg)+-5deg b=(18deg)+-5deg
----------
----------
a=(6deg)+-5deg b=(18deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Use the hole at R = aa
----------
aa=30mm
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
aa=30mm
----------
a=26.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=12deg
----------
a=(130deg)
----------
aa=12deg
----------
a=(130deg)
Information:
Start By:a. remove radiator 1. Attach lifting strap to engine compartment cover. Remove two cotter pins and washers (1), remove four bolts (2). Lift off cover. 2. Loosen hose clamps (3) and (4) and remove hose (5). Remove three bolts (6) and remove ether aid cover (7). 3. Disconnect ether aid line (8), electrical connector (9), and loosen eight 1/4 turn fasteners (10). Remove heat shields (11) and (12). 4. Mark and disconnect starter wires (13) and ground strap (14). 5. Mark and disconnect alternator wires (15) and (16), temperature sending unit wire (17), cable mounting bracket (18), and electrical connector (19). Disconnect and remove flexible exhaust pipe (20). Disconnect two heater hoses (21). 6. Disconnect throttle linkage (22), remove two bolts (23). Set throttle linkage mounting bracket aside. Shut off and disconnect two fuel lines (24). 7. Disconnect throttle cable clip (25). Disconnect electrical wire (26), electrical connector (27) and governor wiring (28). 8. Install tool (A), lifting strap and tool (B) as shown, to support hydraulic pump. Remove twelve hydraulic pump mounting bolts (29). 9. Install lifting chains and remove four bolts and bushings (30).10. Remove engine. The following steps are to install the engine.11. Position engine in vehicle and install four bolts and bushings (30).12. Connect hydraulic pump to engine with twelve mounting bolts (29).13. Remove tooling (A) and (B), and the lifting strap that was supporting the hydraulic pump.14. Connect governor wiring (28), electrical connector (27), and wire (26). Connect throttle cable clip (25).15. Connect two fuel lines (24). Position throttle linkage mounting bracket and secure with two bolts (23). Connect throttle linkage (22).16. Connect two heater hoses (21) and flexible exhaust pipe (20). Connect alternator wires (15) and (16), temperature sending unit wire (17), cable mounting bracket (18) and electrical connector (19).17. Connect starter wires (13) and ground strap (14).18. Replace heat shields (11) and (12), fasten with eight 1/4 turn fasteners. Connect electrical connector (9) and ether aid line (8).19. Replace ether aid cover (7) and secure with three bolts (6). Replace hose (5) and connect with clamps (3) and (4).20. Attach engine compartment cover with four bolts (2) and connect cylinders with cotter pins and washers (1).End By:a. install radiator