Information injection-pump assembly
BOSCH
9 400 613 098
9400613098
ZEXEL
101402-2450
1014022450
HINO
220206370A
220206370a
Rating:
Service parts 101402-2450 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-3520A
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 098
9400613098
ZEXEL
101402-2450
1014022450
HINO
220206370A
220206370a
Zexel num
Bosch num
Firm num
Name
9 400 613 098
220206370A HINO
INJECTION-PUMP ASSEMBLY
W04D-T * K 14BD PE4AD PE
W04D-T * K 14BD PE4AD 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
131424-5720
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
4.8
4.75
4.85
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
12.8
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
93
91
95
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
28
28
Boost pressure
mmHg
210
210
Injection quantity adjustment_02
Adjusting point
C
Rack position
8.5+-0.5
Pump speed
r/min
440
440
440
Average injection quantity
mm3/st.
9.5
8
11
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
E
Rack position
13++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
95
95
105
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
11.2
Boost pressure
kPa
8
4
9.3
Boost pressure
mmHg
60
30
70
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
11.8
Boost pressure
kPa
14.7
14.7
14.7
Boost pressure
mmHg
110
110
110
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Boost compensator stroke: BCL
(5)Rack difference between N = N1 and N = N2
(6)Idle sub spring setting: L1.
----------
K=9 BCL=0.6+-0.1mm N1=1050r/min N2=500r/min L1=9.8+-0.2mm
----------
----------
K=9 BCL=0.6+-0.1mm N1=1050r/min N2=500r/min L1=9.8+-0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=100mm
----------
a=(12deg)+-5deg b=(24deg)+-5deg
----------
aa=100mm
----------
a=(12deg)+-5deg b=(24deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Pump speed aa and rack position bb (to be sealed at delivery)
(3)Use the hole above R = cc
----------
aa=0r/min bb=1-0.5mm cc=25mm
----------
a=21deg+-5deg b=(53deg)
----------
aa=0r/min bb=1-0.5mm cc=25mm
----------
a=21deg+-5deg b=(53deg)
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:
Illustration 23. (2) 141-6737 Adjustable Microgauge.
(7) Top of the 3P-1542 Barrel. (8) 141-6727 Calibration Pump Assembly.1. Place the 141-6737 Adjustable Microgauge on top of the 3P-1542 Barrel of the 141-6727 Calibration Pump Assembly.2. When starting to torque 124-5932 Lever Assemblies, the difference between the face of the 141-6730 Plunger and the 2N-2658 Bolt is about 0.03 mm (.001 in). By setting the 141-6737 Adjustable Microgauge (2) on top of the 141-6727 Calibration Pump Assembly (8), the 141-6737 Plunger can be positioned 25.40 mm (.001 in) above the face of the 3P-1542 Barrel (7).
Illustration 24. (9) 2N-2658 Bolt. (10) 124-5940 Shutoff Lever.3. As the 2N-2658 Bolt (9) is torqued, the 141-6730 Plunger will move down flush with the 3P-1542 Barrel (7) or will be very close to being flush. The calibration can begin from this point. The 2N-2658 Bolts must freely turn in and out of the 124-5940 Shutoff Levers (10) because the calibration depends on where the head of the 2N-2658 Bolt (9) first begins to clamp the 124-5940 Shutoff Lever for the starting point of the calibration.End Play Adjustment
1. In order to save time, use two torque wrenches (color-coding is convenient for distinguishing between the two wrenches). Set one torque wrench to 1.7 N m (15 lb in) and the second torque wrench to N m (35 lb in).
Illustration 25. (1) 124-5941 Shaft. (2) 4N-1826 Dowel on one end of the HSMFS Injection Pump Group. (3) 126-7232 Dowels.2. Adjust the end play in the 124-5941 Shaft. The SMFS 109-0324 Governor And Fuel Injection Pump Group had the dowel in the middle of the sleeve and a large amount of end play in the shaft was acceptable. Now that the 126-7232 Dowels (3) are between two 124-5934 Sleeves, the amount of end play is important. It is necessary that an adjustment be performed to minimize the amount of end play in the 124-5941 Shaft (1).3. The 126-7232 Dowels (3) are located between two 124-5934 Sleeves. Set the 126-7232 Dowels between 0.25 to 0.40 mm (.010 to .016 in) by tapping in the 4N-1826 Dowels (2) until the desired end play is achieved.* With the 1.7 N m (15 lb in) torque wrench, torque the 2N-2658 Bolts to 1.7 N m (15 lb in).* Then use the 4 N m (35 lb in) torque wrench to torque the 2N-2658 Bolts to 3.4 N m (30 lb in) in order to calibrate within specifications.Calibrating the 124-5932 Lever Assemblies.
Illustration 26. Calibrating the 124-5932 Lever Assemblies.
(1) 2N-2658 Bolts. (2) 124-5940 Shutoff Lever.1. Begin with the first 2N-2658 Bolt (1) and turn it until it just begins to clamp (feels snug) on the 124-5940 Shutoff Lever (2).2. Move to the other side and turn the second 2N-2658 Bolt (1) until just begins to clamp (feels snug).* Alternate between sides and tighten each 2N-2658 Bolt about 15 degrees each time.
Illustration 27. View of the HSMFS Injection Pump Group.
(3) Top of the 141-6730 Plunger shown flush with the 3P-1542 Barrel (4).3. Continue until the torque