Information injection-pump assembly
BOSCH
9 400 613 173
9400613173
ZEXEL
101401-1932
1014011932
Rating:
Service parts 101401-1932 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME440837
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 173
9400613173
ZEXEL
101401-1932
1014011932
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
10.4
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
97.5
96.5
98.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
35.3
35.3
Boost pressure
mmHg
265
265
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.7+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-14
14
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
C
Rack position
10.6++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
155
155
160
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
800
800
800
Rack position
R1-0.7
Boost pressure
kPa
14.7
8
21.4
Boost pressure
mmHg
110
60
160
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
R1(10.4)
Boost pressure
kPa
26
23.3
28.7
Boost pressure
mmHg
195
175
215
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)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Boost compensator stroke: BCL
----------
K=12 BCL=0.7+-0.1mm
----------
----------
K=12 BCL=0.7+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(7deg)+-5deg b=(18deg)+-5deg
----------
----------
a=(7deg)+-5deg b=(18deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
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 gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=11deg
----------
a=(130deg)
----------
aa=11deg
----------
a=(130deg)
Information:
(1) Bore in bearing of idler gear ... 28.600 0.048 mm (1.1260 .0019 in) Diameter of shaft for the idler gear ... 28.512 0.013 mm (1.1225 .0005 in)Clearance between bearing and shaft ... 0.028 to 0.150 mm (.0011 to .0059 in)(2) Clearance between gear and body of pump ... 0.05 to 0.66 mm (.002 to .026 in)(3) Diameter of shafts for pump ... 22.217 0.005 mm (.8747 .0002 in) Bore in bearings for shafts ... 22.286 0.051 mm (.8774 .0020 in)Clearance between shafts and bearings ... 0.013 to 0.125 mm (.0005 to .0049 in)(4) Depth that bearings are installed in pump bodies ... 1.52 0.25 mm (.060 .010 in)(5) Gear. Length of gears ... 50.808 0.025 mm (2.0003 .0010 in) Depth of bore in pump body for gears ... 50.935 0.020 mm (2.0053 .0008 in)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in)(6) Length of gears ... 38.070 0.025 mm (1.4988 .0010 in) Depth of bore in pump body for gears ... 38.197 0.020 mm (1.5038 .0008 in)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in)(7) Distance from the end of idler shafts to gear faces ... 21.03 0.13 mm (.828 .005 in) Maximum temperature of gear when shrinking in place ... 398°C (750°F)(8) Distance from the end of the drive shaft to gear face ... 38.23 0.13 mm (1.505 .005 in) Maximum temperature of gear when shrinking in place ... 398°C (750°F)(9) Torque for bolt holding drive gear to drive shaft ... 47 9 N m (35 7 lb ft) Install the bearings in the cover and body for the oil pump so the bearing junctions (joints) are in the position shown (30 15 degrees from centerline).(10) Distance dowel extends from body ... 4.1 0.5 mm (.16 .02 in)(11) Shaft assembly. Distance shaft assembly extends from body ... 30.50 0.25 mm (1.200 .010 in) Before running, lubricate pump with oil. Pump must rotate freely by hand.