Information injection-pump assembly
BOSCH
9 400 619 542
9400619542
ZEXEL
101401-2212
1014012212
Rating:
Service parts 101401-2212 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2161A
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 619 542
9400619542
ZEXEL
101401-2212
1014012212
Zexel num
Bosch num
Firm num
Name
9 400 619 542
220006301B HINO
INJECTION-PUMP ASSEMBLY
A * K 14BC PE4A,5A, PE
A * K 14BC PE4A,5A, PE
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
134424-0920
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
3.2
3.17
3.23
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25
Cal 1-3 deg. 90 89.75 90.25
Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25
Cyl.1-2 deg. 270 269.75 270.25
Injection quantity adjustment
Adjusting point
-
Rack position
12.2
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
78
76
80
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
8.5
7
10
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.2)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
78
77
79
Basic
*
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.65
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
83.9
79.9
87.9
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.4
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
61.6
57.6
65.6
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2(12)
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
49.7
47.7
51.7
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
E
Rack position
R1-0.4
Pump speed
r/min
1280
1280
1280
Average injection quantity
mm3/st.
80.4
76.4
84.4
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_08
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
107
107
117
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R2(12)
Boost pressure
kPa
2
2
4.7
Boost pressure
mmHg
15
15
35
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R1+1.3
Boost pressure
kPa
12.7
12.7
12.7
Boost pressure
mmHg
95
95
95
Timer adjustment
Pump speed
r/min
1010--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
960
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
1060
Advance angle
deg.
1.5
1.2
1.8
Load
4/4
Timer adjustment_04
Pump speed
r/min
1280
Advance angle
deg.
1.8
Load
3/4
Timer adjustment_05
Pump speed
r/min
1600
Advance angle
deg.
4.5
4.2
4.8
Load
4/4
Remarks
Finish
Finish
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)RACK LIMIT
(4)Boost compensator stroke: BCL
----------
T1=F13 BCL=(1.5)+-0.1mm
----------
----------
T1=F13 BCL=(1.5)+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=50mm
----------
a=21.5deg+-5deg b=43deg+-3deg
----------
aa=50mm
----------
a=21.5deg+-5deg b=43deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=13deg+-5deg b=40deg+-5deg
----------
----------
a=13deg+-5deg b=40deg+-5deg
0000001501 ACTUATOR
(a) Screw
(B) Nut
(c) set bolt
(d) control lever
1. Actuator adjustment procedure
(1)Position the control lever (d) in the idling position.
(2)Set the clearance between the control lever (d) and the set bolt (c) to approx. L1.
(3)Loosen the nut (b) and fully tighten the screw (a).
(4)Set the pump speed at N1and measure the rack position when negative pressure P1 is applied to the actuator.
(5)Loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1.
(6)Confirm that control lever (d) returns to the idling position at actuator negative pressure 0.
(7)Repeat procedures (4) to (6) several times and confirm that the control lever (d) moves smoothly.
----------
L1=2mm R1=10.6~10.9mm P1=66.7kPa(500mmHg) N1=300r/min N2=300r/min
----------
----------
L1=2mm R1=10.6~10.9mm P1=66.7kPa(500mmHg) N1=300r/min N2=300r/min
----------
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
Information:
Start By:a. remove fuel injection lines 1. Remove the plug, and move the race until Tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to remove the fuel injection pumps.
To prevent possible personal injury carefully follow the steps below.
2. Put Tool (B), except for the 8T5287 Wrench, in position on the fuel pump housing as shown. Lower the handle to center the adjusting screw with the fuel line seat. With the handle down in the locked position, the adjusting screw must just be in contact with fuel line seat (1). If force is needed to lower the handle or there is a gap, remove the tooling, and make an adjustment to the screw.3. Loosen bushing (2) 1/4 of a turn.4. Put Tool (B) in position on the pump housing with the handle down in the locked position as shown.5. Remove bushing (2) from the pump housing.6. Carefully and slowly lift the handle to release the spring force. Remove the tooling. 7. Install Tool (C) on fuel pump (4) as shown.8. Remove seal (3) and fuel pump (4) from the fuel pump housing. 9. Remove spacers (5) from the pump housing. There must be a pump installed on either side of the pump to be removed to install Tool (B). If there is no pump, take a pump already removed, and remove the spring so there will be no spring force, and install it in the pump housing. See Install Fuel Pump. Spacers (5) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and cannot be mixed.Install Fuel Injection Pumps
1. Install spacers (5) in the fuel pump housing.2. Move the rack until Tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Install a fuel pump without its spring so that Tool (B) can be installed. See Step 5 for correct fuel pump installation. 4. Install Tool (C) on the bonnet of the fuel pump as shown.5. Install the fuel pump in the pump housing with the saw cut (slot) (9) in the gear in alignment with small pin (6) in the lifter assembly and groove (8) in the barrel in alignment with large pin (7) in the pump housing. 6. Install the seal and bushing (2) on the fuel pump.7. Put Tool (B) in position on the fuel pump housing as shown.8. Lower the handle slowly and carefully. If the fuel pump is not installed correctly, the handle will not go all the way down. Do not try to use force on it. Remove and install the tooling and the fuel pump again.9. Make sure the seal is in its correct position, and start to tighten bushing (2). Remove the tooling, and tighten the bushing to a torque of 260 15 N m (190
To prevent possible personal injury carefully follow the steps below.
2. Put Tool (B), except for the 8T5287 Wrench, in position on the fuel pump housing as shown. Lower the handle to center the adjusting screw with the fuel line seat. With the handle down in the locked position, the adjusting screw must just be in contact with fuel line seat (1). If force is needed to lower the handle or there is a gap, remove the tooling, and make an adjustment to the screw.3. Loosen bushing (2) 1/4 of a turn.4. Put Tool (B) in position on the pump housing with the handle down in the locked position as shown.5. Remove bushing (2) from the pump housing.6. Carefully and slowly lift the handle to release the spring force. Remove the tooling. 7. Install Tool (C) on fuel pump (4) as shown.8. Remove seal (3) and fuel pump (4) from the fuel pump housing. 9. Remove spacers (5) from the pump housing. There must be a pump installed on either side of the pump to be removed to install Tool (B). If there is no pump, take a pump already removed, and remove the spring so there will be no spring force, and install it in the pump housing. See Install Fuel Pump. Spacers (5) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and cannot be mixed.Install Fuel Injection Pumps
1. Install spacers (5) in the fuel pump housing.2. Move the rack until Tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Install a fuel pump without its spring so that Tool (B) can be installed. See Step 5 for correct fuel pump installation. 4. Install Tool (C) on the bonnet of the fuel pump as shown.5. Install the fuel pump in the pump housing with the saw cut (slot) (9) in the gear in alignment with small pin (6) in the lifter assembly and groove (8) in the barrel in alignment with large pin (7) in the pump housing. 6. Install the seal and bushing (2) on the fuel pump.7. Put Tool (B) in position on the fuel pump housing as shown.8. Lower the handle slowly and carefully. If the fuel pump is not installed correctly, the handle will not go all the way down. Do not try to use force on it. Remove and install the tooling and the fuel pump again.9. Make sure the seal is in its correct position, and start to tighten bushing (2). Remove the tooling, and tighten the bushing to a torque of 260 15 N m (190