Information injection-pump assembly
BOSCH
9 400 613 044
9400613044
ZEXEL
101402-9621
1014029621
Rating:
Service parts 101402-9621 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
9 400 613 044
9400613044
ZEXEL
101402-9621
1014029621
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
3.3
3.25
3.35
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
10.3
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
65
64
66
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7+-0.5
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
9
8
10
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.
85
80
90
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
(7)Rack difference to N = N2
----------
K=15 N1=750r/min N2=450r/min
----------
----------
K=15 N1=750r/min N2=450r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=11deg+-5deg b=22deg+-5deg
----------
----------
a=11deg+-5deg b=22deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At delivery
----------
----------
a=58deg+-5deg b=53deg+-5deg
----------
----------
a=58deg+-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:
Start By:a. remove automatic timing advance unit
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
Before any timing gears are removed, make sure "C" on the crankshaft gear is in alignment with "C" mark on the camshaft gear. 1. Remove bolts, plate (1) and fuel pump idler gear (2). 2. Remove bearing from idler gear (2) with tool (A). 3. Remove four bolts (3) and camshaft gear (4). 4. Remove bolts that are used to fasten shield (5) in position between the fuel pump and the exhaust manifold. Slide shield back from the timing cover plate.5. Remove the three nuts (6). 6. Remove six bolts (7). Remove the timing gear plate and the gasket. The following steps are to install the timing gears and plate.7. Clean the old gasket from the contact surfaces of the timing gear plate and cylinder block. Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block.8. Be sure the O-ring seals are in position on the end of the fuel injection pump housing. Put the timing gear plate in position on the cylinder block and install the six bolts (7). Install nuts (6).
After the timing gear plate is installed, be sure the rack is free to move in the fuel injection pump housing. The O-ring seal on the drive end of the fuel injection pump housing can hold the rack and prevent free rack movement. Rack movement can be seen through hole in the timing gear plate just above where the fuel pump gear is mounted. If the rack does not move freely, remove the timing gear plate and check the O-ring seal on the drive end of the fuel injection pump housing. If the rack does not move freely, the engine can over speed and be damaged. Serious personal injury can be the result.
9. Install camshaft gear (4) with the "C" mark on the camshaft gear in alignment with the "C" mark on the crankshaft gear as shown in the illustration in the Specification section of this manual. Tighten the volts to a torque of 55 7 N m (41 5 lb ft).10. Use tooling (A) to install the bearing in idler gear (2). The end of the bearing must be 1.52 .025 mm (.060 .010 in) below the face of the gear hub.11. Be sure the oil hole in the shaft for gear (2) is open. Install idler gear (2). Put the plate on position with the finished side toward gear (2) and install the bolts.12. Install shield (5) and the four bolts.End By:a. install automatic timing advance unit
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
Before any timing gears are removed, make sure "C" on the crankshaft gear is in alignment with "C" mark on the camshaft gear. 1. Remove bolts, plate (1) and fuel pump idler gear (2). 2. Remove bearing from idler gear (2) with tool (A). 3. Remove four bolts (3) and camshaft gear (4). 4. Remove bolts that are used to fasten shield (5) in position between the fuel pump and the exhaust manifold. Slide shield back from the timing cover plate.5. Remove the three nuts (6). 6. Remove six bolts (7). Remove the timing gear plate and the gasket. The following steps are to install the timing gears and plate.7. Clean the old gasket from the contact surfaces of the timing gear plate and cylinder block. Install a new gasket on the cylinder block. Cut the gasket even with the bottom face of the cylinder block.8. Be sure the O-ring seals are in position on the end of the fuel injection pump housing. Put the timing gear plate in position on the cylinder block and install the six bolts (7). Install nuts (6).
After the timing gear plate is installed, be sure the rack is free to move in the fuel injection pump housing. The O-ring seal on the drive end of the fuel injection pump housing can hold the rack and prevent free rack movement. Rack movement can be seen through hole in the timing gear plate just above where the fuel pump gear is mounted. If the rack does not move freely, remove the timing gear plate and check the O-ring seal on the drive end of the fuel injection pump housing. If the rack does not move freely, the engine can over speed and be damaged. Serious personal injury can be the result.
9. Install camshaft gear (4) with the "C" mark on the camshaft gear in alignment with the "C" mark on the crankshaft gear as shown in the illustration in the Specification section of this manual. Tighten the volts to a torque of 55 7 N m (41 5 lb ft).10. Use tooling (A) to install the bearing in idler gear (2). The end of the bearing must be 1.52 .025 mm (.060 .010 in) below the face of the gear hub.11. Be sure the oil hole in the shaft for gear (2) is open. Install idler gear (2). Put the plate on position with the finished side toward gear (2) and install the bolts.12. Install shield (5) and the four bolts.End By:a. install automatic timing advance unit