Information injection-pump assembly
BOSCH
9 400 610 491
9400610491
ZEXEL
101402-9400
1014029400
Rating:
Service parts 101402-9400 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 491
9400610491
ZEXEL
101402-9400
1014029400
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
131424-1520
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
3.6
3.55
3.65
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
9.8
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
64.5
63.5
65.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7.1+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
12.5
11.5
13.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
70
65
75
Fixing the lever
*
Rack limit
*
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)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Rack difference from N = N1
----------
K=14 N1=700r/min
----------
----------
K=14 N1=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=4deg+-5deg b=17deg+-5deg
----------
----------
a=4deg+-5deg b=17deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=7deg+-5deg b=53deg+-5deg
----------
----------
a=7deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
(1) Body assembly. Install piston with "FRONT" toward front of engine. Assemble so the markings "FRONT" on the piston body assembly and the forging part number on the connecting rod assembly point in opposite directions. Install connecting rod and piston group with rod forging part number to the rear of the engine. The rear of the engine is the flywheel end. Thoroughly lubricate the piston group with clean engine oil just before inserting into block group.(2) Connecting rod.Top And Intermediate Ring
Install piston ring with "UP" side toward top of piston.(3) Top Ring has the mark "UP-1". Clearance between ends of piston ring when installed in a cylinder with a bore size of 105.025 mm (4.1348 in) ... 0.525 0.125 mm (.021 .005 in)Increase in clearance between ends of piston ring for each 0.03 mm (.001 in) increase in cylinder bore size ... 0.09 mm (.004 in)(4) Intermediate Ring has the
Install piston ring with "UP" side toward top of piston.(3) Top Ring has the mark "UP-1". Clearance between ends of piston ring when installed in a cylinder with a bore size of 105.025 mm (4.1348 in) ... 0.525 0.125 mm (.021 .005 in)Increase in clearance between ends of piston ring for each 0.03 mm (.001 in) increase in cylinder bore size ... 0.09 mm (.004 in)(4) Intermediate Ring has the