Information injection-pump assembly
BOSCH
9 400 611 934
9400611934
ZEXEL
101401-1910
1014011910
Rating:
Service parts 101401-1910 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
9 400 611 934
9400611934
ZEXEL
101401-1910
1014011910
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
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
10.7
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
76
75
77
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.3+-0.5
Pump speed
r/min
445
445
445
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
11.2++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
45
45
50
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
350
Advance angle
deg.
2.5
2
3
Remarks
Start
Start
Timer adjustment_03
Pump speed
r/min
500
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)Torque spring does not operate.
(4)RACK LIMIT
(5)Set idle sub-spring
(6)Main spring setting
(7)Rack difference between N = N1 and N = N2
----------
K=6 N1=900r/min N2=600r/min
----------
----------
K=6 N1=900r/min N2=600r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=2deg+-5deg b=13deg+-5deg
----------
----------
a=2deg+-5deg b=13deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At solenoid operation and speed = aa, rack position must be bb or less (at voltage cc).
----------
aa=0r/min bb=7.6mm cc=24V
----------
a=27deg+-5deg b=53deg+-5deg
----------
aa=0r/min bb=7.6mm cc=24V
----------
a=27deg+-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:
(1) Cylinder head bolts and nuts: 1. Put clean engine oil on the threads of bolts and nuts. Tighten bolts and nuts (cold), numbers 1 thru 32 in order shown, to a torque of 155 N m (115 lb.ft.)2. Tighten small bolts (cold), numbers 33 thru 38, to a torque of ... 38 N m (28 lb.ft.)Retighten the cylinder head bolts and nuts after the engine has run and the coolant temperature is no less than 77°C (170°F) as follows:a. If the bolts and nuts move before the correct torque (above) is reached, tighten the bolts and nuts (hot) to the torques that follow: No. 1 thru 32 ... 142 N m (105 lb.ft.)No. 33 thru 38 ... 38 N m (28 lb.ft.)b. If the bolts and nuts do not move before the correct torque is reached, back each one off 30 to 60° and retighten them again in the order shown to the torques shown in Step a. After all the bolts and nuts are retightened, check the first 10 positions again to make sure they are tightened to the correct torque.(2) Torque for nuts that hold injectors to cylinder head ... 17 N m (12 lb.ft.) Replace the copper washer and rubber seal between the head and the injector every time the injector is removed. (See Fuel Injector Installation in TESTING AND ADJUSTING.) Make sure the correct thickness washer is installed. They are as follows: 6.3544 Engines ... 2.03 mm (.080 in.)T6.3544 Engines ... 0.71 mm (.028 in.)(3) Torque for fuel line nuts ... 20 N m (15 lb.ft.)(4) Tighten rocker shaft assembly bolts and nuts from the center outward to a torque of ... 75 N m (55 lb.ft.)(5) Valve clearance (cold): Intake ... 0.20 mm (.008 in.)Exhaust ... 0.46 mm (.018 in.)(6) Maximum permissible injector nozzle projection below cylinder head face (with seating washers in position) after skimming: 6.3544 Engines ... 3.45 mm (.136 in.) max.T6.3544 Engines ... 4.67 mm (.184 in.) max.Skimming allowance ... 0.30 mm (.012 in.) max.(7) Depth of cylinder head (new) ... 94.87 to 95.63 mm (3.735 to 3.765 in.) Minimum depth of cylinder head (after skimming) ... 94.87 mm (3.735 in.)Maximum permissible amount of bow (curve of cylinder head): across width (transverse) ... 0.13 mm (.005 in.)across length (longitudinal) ... 0.25 mm (.010 in.)(See Cylinder Head Check in TESTING AND ADJUSTING)