Information injection-pump assembly
BOSCH
9 400 611 218
9400611218
ZEXEL
101401-2313
1014012313
HINO
220204500C
220204500c
Rating:
Service parts 101401-2313 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2601A
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 611 218
9400611218
ZEXEL
101401-2313
1014012313
HINO
220204500C
220204500c
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
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
A
Rack position
12.8
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
115
113
117
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
78.6
78.6
Boost pressure
mmHg
590
590
Injection quantity adjustment_02
Adjusting point
C
Rack position
9+-0.5
Pump speed
r/min
405
405
405
Average injection quantity
mm3/st.
9
7.5
10.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
900
900
900
Rack position
R1-1.85
Boost pressure
kPa
16
13.3
18.7
Boost pressure
mmHg
120
100
140
Boost compensator adjustment_02
Pump speed
r/min
900
900
900
Rack position
R1(12.8)
Boost pressure
kPa
65.3
58.6
72
Boost pressure
mmHg
490
440
540
Timer adjustment
Pump speed
r/min
1275--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1225
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
0
0
0
Load
4/4
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_04
Pump speed
r/min
1450
Advance angle
deg.
3.25
2.95
3.55
Load
4/4
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)Set idle sub-spring
(4)Main spring setting
(5)Boost compensator stroke
----------
K=10
----------
----------
K=10
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=26deg+-5deg
----------
----------
a=10deg+-5deg b=26deg+-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=1-0.2mm
----------
a=21deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.2mm
----------
a=21deg+-5deg b=(55deg)
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:
Ejector Guide Rollers
(631 & 637)
Adjust
1. The ejector should operate freely without binding. To adjust the guide rollers, loosen the roller shaft clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller. 3. Tighten the clamping bolt. Clearance between the guide rollers and the scraper bowl should be 3.00 to 20.00 mm (.118 to .787 in).Ejector Carrier Rollers
(631 & 637)
Adjust
1. The ejector should operate freely without dragging. To adjust the carrier rollers, loosen the clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller.3. Tighten the clamping bolt. Clearance between the bottom of the ejector and the bottom of the bowl should be 1.0 to 13.0 mm (.04 to .50 in).Ejector Support Rollers
(631 & 637)
Adjust
1. The ejector should operate freely without dragging. To adjust the carrier rollers, loosen the clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller. 3. Tighten the clamping bolt. The distance between rollers, outside to outside, should be .00 to 6.00 mm (.00 to .236 in) less than the narrowest dimension between the roller guide tracks.Refer to the Service Manual for your machine or contact your Caterpillar dealer for the correct adjustment procedure.Ejector Carriage Rollers
(639)
Adjust
Do not get under the push frame unless the front engine is stopped and the ejector floor is blocked.
1. Install pin in the position that will block movement of the carriage.See "Blocking the Ejector Floor Closed" in the "Safety" section of the Operation (Operator's) Guide. 2. The carriage should operate freely without binding. To adjust the carriage rollers, loosen the roller shaft clamping bolt. 3. Turn the roller (eccentric) shaft to position the rollers. 4. Tighten the clamping bolt. The distance between rollers, outside to outside, should be .00 to 1.50 mm (.00 to .060 in) less than the narrowest dimension between the guide tracks on the push frame.
(631 & 637)
Adjust
1. The ejector should operate freely without binding. To adjust the guide rollers, loosen the roller shaft clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller. 3. Tighten the clamping bolt. Clearance between the guide rollers and the scraper bowl should be 3.00 to 20.00 mm (.118 to .787 in).Ejector Carrier Rollers
(631 & 637)
Adjust
1. The ejector should operate freely without dragging. To adjust the carrier rollers, loosen the clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller.3. Tighten the clamping bolt. Clearance between the bottom of the ejector and the bottom of the bowl should be 1.0 to 13.0 mm (.04 to .50 in).Ejector Support Rollers
(631 & 637)
Adjust
1. The ejector should operate freely without dragging. To adjust the carrier rollers, loosen the clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller. 3. Tighten the clamping bolt. The distance between rollers, outside to outside, should be .00 to 6.00 mm (.00 to .236 in) less than the narrowest dimension between the roller guide tracks.Refer to the Service Manual for your machine or contact your Caterpillar dealer for the correct adjustment procedure.Ejector Carriage Rollers
(639)
Adjust
Do not get under the push frame unless the front engine is stopped and the ejector floor is blocked.
1. Install pin in the position that will block movement of the carriage.See "Blocking the Ejector Floor Closed" in the "Safety" section of the Operation (Operator's) Guide. 2. The carriage should operate freely without binding. To adjust the carriage rollers, loosen the roller shaft clamping bolt. 3. Turn the roller (eccentric) shaft to position the rollers. 4. Tighten the clamping bolt. The distance between rollers, outside to outside, should be .00 to 1.50 mm (.00 to .060 in) less than the narrowest dimension between the guide tracks on the push frame.