Information injection-pump assembly
BOSCH
9 400 610 424
9400610424
ZEXEL
101401-7440
1014017440
Rating:
Service parts 101401-7440 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97119-811-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 424
9400610424
ZEXEL
101401-7440
1014017440
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
134424-3920
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 D R=D
Point D R=D
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
12.4
Pump speed
r/min
1310
1310
1310
Average injection quantity
mm3/st.
73.5
71.9
75.1
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
9.5+-0.5
Pump speed
r/min
315
315
315
Average injection quantity
mm3/st.
10
8.7
11.3
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(12.4)
Pump speed
r/min
1310
1310
1310
Average injection quantity
mm3/st.
73.5
72.5
74.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.5
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
87.5
83.5
91.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.45
Pump speed
r/min
520
520
520
Average injection quantity
mm3/st.
45.6
41.6
49.6
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1-0.3
Pump speed
r/min
960
960
960
Average injection quantity
mm3/st.
61.5
57.5
65.5
Fixing the lever
*
Timer adjustment
Pump speed
r/min
-
Advance angle
deg.
0
0
0
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
4.8
4.3
5.3
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
5
4.5
5.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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=M40
----------
----------
T1=M40
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
(2)-
----------
----------
a=38deg+-5deg b=37deg+-3deg
----------
----------
a=38deg+-5deg b=37deg+-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
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)At the No 1 cylinder's beginning of injection, align with the aligning mark seen through the bracket's check hole and mark the A/T's bevel C1.
(5)B.T.D.C.: aa
----------
aa=7deg
----------
a=(60deg) b=(85deg)
----------
aa=7deg
----------
a=(60deg) b=(85deg)
Information:
Typical Example1. Remove bolts (1) from the alternator bracket.2. Remove the bolts that hold plate (3) and remove the plate.3. Disconnect water line (2) from the air compressor. Turn the water line tee toward the lifting bracket in order to provide clearance to remove the head bolt. 4. Remove bolts (4) and (5) that hold the cylinder head assembly to the cylinder block.5. Fasten a hoist and remove the cylinder head assembly. The weight is approximately 135 kg (300 lb).
Do not put the cylinder head assembly down on a flat surface. This can cause damage to the fuel injection valves.
6. Remove the gasket and seals from the spacer plate.Install Cylinder Head Assembly
Be sure a new gasket has been installed between the spacer plate and the cylinder block. See topic, "Remove & Install Spacer Plate". 1. Thoroughly clean the spacer plate and the bottom surface of the cylinder head assembly. Install a new head gasket, new seals (1) and two O-ring seals (2). 2. Fasten a hoist and put the cylinder head assembly (3) in position on the cylinder block.3. Tighten the bolts in sequence shown in Illustration D11970.
(1) Large bolts (3/4 inch). Put 6V4876 Molycoat Paste Lubricant on bolt threads and between washers and underside of bolt heads.(2) Small bolts (3/8 inch). See Step 4h.4. Install the cylinder head bolts and washers. Tighten the bolts in sequence shown.a. Tighten bolts 1 through 14 in number sequence to 270 25 N m (200 20 lb ft).b. Tighten bolts 1 through 14 in number sequence to 470 20 N m (345 15 lb ft).c. Tighten bolts 1 through 14 in number sequence again to 470 20 N m (345 15 lb ft).d. Install the rocker arm shafts for the engine valves and the remaining (3/4 in) bolts and/or compression brake studs.e. Tighten bolts 15 through 26 in number sequence to 270 25 N m (200 20 lb ft).f. Tighten bolts 15 through 26 in number sequence to 450 20 N m (330 15 lb ft).g. Tighten bolts 15 through 26 in number sequence again to 450 20 N m (330 15 lb ft).h. Tighten the thirteen small bolts (2) to 45 7 N m (33 5 lb ft).5. Make an adjustment to the valves to have a clearance of 0.38 mm (.015 in) for intake and 0.76 mm (.030 in) for exhaust. Tighten the locknuts for the valve adjustment screws to a torque of 28 4 N m (21 3 lb ft).6. Install the valve cover bases and the inner fuel lines. See topic, "Install Rocker Shaft Assemblies & Push Rods".7. Install the valve covers. See topic, "Install Valve Covers".
Typical Example8. Install plate (4).9. Connect the water line to the air compressor.10. Install bolts (5) for the alternator bracket.End By:a. install exhaust manifoldb. install fuel injection linesc. install aftercooler housingd. install water temperature regulatore. install rocker shaft assemblies and push rods