Information injection-pump assembly
BOSCH
9 400 613 690
9400613690
ZEXEL
101401-4302
1014014302
ISUZU
8970483063
8970483063
Rating:
Service parts 101401-4302 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97114-016-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 690
9400613690
ZEXEL
101401-4302
1014014302
ISUZU
8970483063
8970483063
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
131424-4920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
4.1
4.05
4.15
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor 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
-
Rack position
11.9
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
71
69.4
72.6
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
10+-0.5
Pump speed
r/min
285
285
285
Average injection quantity
mm3/st.
23.5
22.2
24.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.9)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
71
70
72
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.2
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
83.5
79.5
87.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
80
80
112
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1375--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1325
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
3.3
2.8
3.8
Timer adjustment_04
Pump speed
r/min
1600--
Advance angle
deg.
5
4.5
5.5
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.
----------
T1=H97
----------
----------
T1=H97
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=41deg+-5deg b=(36deg)+-3deg
----------
----------
a=41deg+-5deg b=(36deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
0000001501 FICD
(A) applied negative pressure
(B) Screw
(c) Nut
1. Set the actuator as described below.
(1)Confirm that there is clearance between the actuator lever and the speed lever.
(2)Loosen the nut (C).
(3)Push in the screw (B).
(4)Apply P1 from the actuator (A) part.
(5)Pull out the screw (B) slowly.
(6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra.
(7)Torque the nut (C) to T1.
(8)Apply P2 several times.
(9)Confirm that the actuator functions normally.
(10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=450r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=450r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)Stamping position on the A/T outer rim
(4)Pump bracket check hole position.
(5)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1.
(6)B.T.D.C.: aa
----------
aa=10deg
----------
a=(60deg) b=(85deg)
----------
aa=10deg
----------
a=(60deg) b=(85deg)
Information:
(1) Bore in idler gear bearing ... 28.600 0.061 mm (1.1260 .0024 in) Diameter of idler gear shaft ... 28.512 0.013 mm (1.1225 .0005 in)Clearance between bearing and shaft ... .014 to .162 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 ... .013 to .125 mm (.0010 to .0050 in)(4) Depth that bearings are installed in pump bodies ... 1.52 0.25 mm (.060 .010 in)(5) Length of gears ... 50.808 0.025 mm (2.0003 0.0010 in) Depth of bore in pump body for gears ... 50.935 0.020 mm (2.0053 0.0008 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 0.0010 in) Depth of bore in pump body for gears ... 38.197 0.020 mm (1.5038 0.0008 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 the idler shafts to gear faces ... 21.03 0.13 mm (.828 .005 in) Maximum temperature of gear when shrinking in place ... 400°C (750°F)(8) Distance from the end of the drive shaft to gear face ... 38.23 0.13 mm (1.505 0.005 in) Maximum temperature of gear when shrinking in place ... 400°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.(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 (1.201 0.010 in)
Section A-A
Oil Pump Bypass Spring(12) 115-7545 Spring: Length under test force ... 22.22 mm (.875 in)Test force ... 780 N (175 lb)Free length after test ... 25.4 mm (1.00 in)Outside diameter ... 18.54 mm (.730 in) Before running, lubricate pump with oil. Pump must rotate freely by hand.
Section A-A
Oil Pump Bypass Spring(12) 115-7545 Spring: Length under test force ... 22.22 mm (.875 in)Test force ... 780 N (175 lb)Free length after test ... 25.4 mm (1.00 in)Outside diameter ... 18.54 mm (.730 in) Before running, lubricate pump with oil. Pump must rotate freely by hand.