Information injection-pump assembly
BOSCH
9 400 611 381
9400611381
ZEXEL
101402-9770
1014029770
Rating:
Service parts 101402-9770 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
9 400 611 381
9400611381
ZEXEL
101402-9770
1014029770
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
9.3
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
41.9
40.9
42.9
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 between N = N1 and N = N2
----------
K=16 N1=1250r/min N2=450r/min
----------
----------
K=16 N1=1250r/min N2=450r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=55mm
----------
a=23deg+-5deg b=28deg+-5deg
----------
aa=55mm
----------
a=23deg+-5deg b=28deg+-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 valve covers 1. Use tooling (A), and disconnect fuel line (1) at each end. Remove the fuel line from the engine. 2. Use tool (B), and remove retainer (2) from the adapter.3. Remove the fuel injection nozzles with tooling (C) as follows:a. Install the 6V6983 Adapter and the 8T3199 Screw into nozzle assembly (3).b. Install the 8T3198 Tube over the 8T3199 Screw.c. Use the 1B4206 Nut on the 8T3199 Screw.d. Use the 1B4206 Nut on the 8T3199 Screw to pull the fuel injection nozzle from the adapter.4. Remove compression seal (4) and carbon dam seal (8) from fuel injection nozzle (3).5. Use tool (D), and remove adapter (6) from the cylinder head.6. Remove gasket (7) and seal (5) from adapter (6). The following steps are for installation of the fuel injection nozzles and adapters.7. Use tool (E) to clean the bore in adapter (6). Use an open end wrench or tap driver to turn tool (E).8. Inspect seal (5) for damage or wear. Replace the seal if necessary.9. Put washer (7) and seal (5) in position on adapter (6).10. Put liquid soap in the bores of the cylinder head and on seals (5) in the adapters.11. Put 5P3931 Anti-Seize Compound on the threads of adapter (6), and install the adapter in the cylinder head assembly.12. Use tool (D), and tighten the adapter to a torque of 205 14 N m (150 10 lb.ft.).
Make sure the correct compression seal washer (4) is used when the nozzle assembly is installed in the adapter. Only copper washers are to be used with this adapter.
13. Install compression seal washer (4), and use tool (F) to install carbon dam seal (8) on the fuel injection nozzle.14. Put fuel injection nozzle (3) in position in the adapter, and install retainer (2).15. Use tool (B) to tighten retainer (2) to a torque of 48 7 N m (35 5 lb.ft.).16. Install fuel line (1). Tighten the nuts on the fuel line with tooling (A) to a torque of 40 7 N m (30 5 lb.ft.).End By:a. install valve covers
Make sure the correct compression seal washer (4) is used when the nozzle assembly is installed in the adapter. Only copper washers are to be used with this adapter.
13. Install compression seal washer (4), and use tool (F) to install carbon dam seal (8) on the fuel injection nozzle.14. Put fuel injection nozzle (3) in position in the adapter, and install retainer (2).15. Use tool (B) to tighten retainer (2) to a torque of 48 7 N m (35 5 lb.ft.).16. Install fuel line (1). Tighten the nuts on the fuel line with tooling (A) to a torque of 40 7 N m (30 5 lb.ft.).End By:a. install valve covers