Information injection-pump assembly
BOSCH
9 400 610 496
9400610496
ZEXEL
101402-9520
1014029520
MITSUBISHI-HEAV
3426102090
3426102090
Rating:
Service parts 101402-9520 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
34361-01010
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 496
9400610496
ZEXEL
101402-9520
1014029520
MITSUBISHI-HEAV
3426102090
3426102090
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
131424-5720
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
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
8.8
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
74.6
73.6
75.6
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
5.9+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60
60
65
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 between N = N1 and N = N2
----------
K=9 N1=900r/min N2=700r/min
----------
----------
K=9 N1=900r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=1deg+-5deg b=20deg+-5deg c=35deg+-3deg
----------
----------
a=1deg+-5deg b=20deg+-5deg c=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Hold the boss against the stop side
(2)Use the hole at R = aa
----------
aa=60mm
----------
a=53deg+-5deg b=26.5deg+-5deg c=(9deg)
----------
aa=60mm
----------
a=53deg+-5deg b=26.5deg+-5deg c=(9deg)
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:
Start By:a. remove fuel injection lines
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove bolts (1) and fan guard (2). 2. Loosen bolts (7), (9) and (10). Remove belts (8).3. Remove bolt (4) to clip. Remove grease line (3).4. Remove nuts (6). Remove cover (5) and the gasket. 5. Loosen bolt (12) enough to leave a gap of 3.18 mm (.125 in) between washers (11) and the fuel pump drive gear.6. Install tool (A) as shown. Tighten the stud to pull the fuel pump drive gear loose from the taper on the fuel injection pump camshaft.7. Remove tool (A), bolt (12), and washer (11). 8. Identify and disconnect wires (13).9. Remove tube assemblies (15) and (18).10. Remove two bolts (14), fuel transfer pump (17), and the O-ring seal.11. Remove bolts (16), the filter base, the gasket, and filter (19). 12. Fasten the fuel injection pump housing and governor to a hoist.13. Remove two bolts (22), three nuts (21), and the fuel injection pump housing and governor. The weight of the fuel injection pump housing and governor is 29 kg (64 lb.).14. Remove the two O-ring seals from the bottom of the fuel injection pump housing and governor. 15. Loosen screw (25). Remove two screws (26), control assembly (23) and spacers (24).Install Fuel Injection Pump Housing And Governor
Start By:a. remove fuel injection linesb. remove valve cover Number 1 piston must be set at top dead center (TDC) to perform all timing procedures. The engine is seen from the flywheel end when direction of crankshaft rotation is given. 1. Remove the starter.2. Install tool (B) on flywheel housing as shown.3. To find TDC for No. 1 piston;a. Turn the flywheel clockwise (opposite the direction of engine rotation) approximately 30 degrees. This removes all play from the timing gears. If you go past the bolt hole, you must repeat Step (a).b. Turn the flywheel counterclockwise until a 3/8" - 16 x 2 1/4" NC bolt (27) can be installed in the flywheel through the hole in the flywheel housing. The No. 1 and No. 6 pistons are now at top center position. The No. 1 piston is on the compression stroke when the valves of the No. 1 cylinder are closed. The rocker must be free to move up and down.4. If No. 1 piston is not on the compression stroke, remove the 3/8" - 16 x 2 1/4" NC bolt (27) and turn the flywheel 360° counterclockwise. Install the 3/8" bolt as before. The No. 1 piston is now at TDC.
Typical Example5. Install tooling (C) in the fuel injection pump housing as shown. Push on tooling (C) and turn injection pump camshaft (32). When tooling (C) engages the groove (slot) in the camshaft, the fuel injection pump is in the No. 1 piston TDC position.6. Be sure O-ring seals (28), (29), (30) and (31) are in position on the fuel injection pump housing and governor. Put clean engine oil
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove bolts (1) and fan guard (2). 2. Loosen bolts (7), (9) and (10). Remove belts (8).3. Remove bolt (4) to clip. Remove grease line (3).4. Remove nuts (6). Remove cover (5) and the gasket. 5. Loosen bolt (12) enough to leave a gap of 3.18 mm (.125 in) between washers (11) and the fuel pump drive gear.6. Install tool (A) as shown. Tighten the stud to pull the fuel pump drive gear loose from the taper on the fuel injection pump camshaft.7. Remove tool (A), bolt (12), and washer (11). 8. Identify and disconnect wires (13).9. Remove tube assemblies (15) and (18).10. Remove two bolts (14), fuel transfer pump (17), and the O-ring seal.11. Remove bolts (16), the filter base, the gasket, and filter (19). 12. Fasten the fuel injection pump housing and governor to a hoist.13. Remove two bolts (22), three nuts (21), and the fuel injection pump housing and governor. The weight of the fuel injection pump housing and governor is 29 kg (64 lb.).14. Remove the two O-ring seals from the bottom of the fuel injection pump housing and governor. 15. Loosen screw (25). Remove two screws (26), control assembly (23) and spacers (24).Install Fuel Injection Pump Housing And Governor
Start By:a. remove fuel injection linesb. remove valve cover Number 1 piston must be set at top dead center (TDC) to perform all timing procedures. The engine is seen from the flywheel end when direction of crankshaft rotation is given. 1. Remove the starter.2. Install tool (B) on flywheel housing as shown.3. To find TDC for No. 1 piston;a. Turn the flywheel clockwise (opposite the direction of engine rotation) approximately 30 degrees. This removes all play from the timing gears. If you go past the bolt hole, you must repeat Step (a).b. Turn the flywheel counterclockwise until a 3/8" - 16 x 2 1/4" NC bolt (27) can be installed in the flywheel through the hole in the flywheel housing. The No. 1 and No. 6 pistons are now at top center position. The No. 1 piston is on the compression stroke when the valves of the No. 1 cylinder are closed. The rocker must be free to move up and down.4. If No. 1 piston is not on the compression stroke, remove the 3/8" - 16 x 2 1/4" NC bolt (27) and turn the flywheel 360° counterclockwise. Install the 3/8" bolt as before. The No. 1 piston is now at TDC.
Typical Example5. Install tooling (C) in the fuel injection pump housing as shown. Push on tooling (C) and turn injection pump camshaft (32). When tooling (C) engages the groove (slot) in the camshaft, the fuel injection pump is in the No. 1 piston TDC position.6. Be sure O-ring seals (28), (29), (30) and (31) are in position on the fuel injection pump housing and governor. Put clean engine oil