Information injection-pump assembly
BOSCH
9 400 611 160
9400611160
ZEXEL
101495-3422
1014953422
Rating:
Service parts 101495-3422 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6205-11-3100
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
101495-3422
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-7073
as _
Cross reference number
BOSCH
9 400 611 160
9400611160
ZEXEL
101495-3422
1014953422
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
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
1-2-4-3
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5
Cyl.1-2 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
Cal 1-3 deg. 270 269.5 270.5
Cal 1-3 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
63.5
62.5
64.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.4+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
8
7
9
Max. variation between cylinders
%
0
-15
15
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.
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 CAP: R1
(4)Set idle sub-spring
----------
K=9 R1=(17.5)mm
----------
----------
K=9 R1=(17.5)mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa. ( At delivery )
(2)Set the pump speed at bb.
(3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=1deg+-5deg b=25deg+-5deg c=6deg+-5deg
----------
aa=900r/min bb=750r/min
----------
a=1deg+-5deg b=25deg+-5deg c=6deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, speed = bb (stamp at delivery)
(2)No return spring
----------
aa=1-0.5mm bb=0r/min
----------
a=27.5deg+-5deg b=(55deg)
----------
aa=1-0.5mm bb=0r/min
----------
a=27.5deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Position of key groove at No 1 cylinder's beginning of injection
(3)Stamp aligning marks on the pump housing flange.
(4)-
(5)-
----------
----------
a=58deg+-3deg b=2deg+-30min
----------
----------
a=58deg+-3deg b=2deg+-30min
Information:
Introduction
The valve housing may crack causing certain remanufactured fuel injectors to malfunction.Problem
Some remanufactured valve bodies on fuel injectors have been cracking under high pressure. This crack in the valve body can cause fuel to get into the engine oil.Solution
All 10R-0957 Injector Gp Fuel with serial number range 848368 to 850132 should be removed from the parts stock. 10R-0960 Injector Gp Fuel , 10R-0961 Injector Gp Fuel , 10R-0963 Injector Gp Fuel , and 10R-1268 Injector Gp Fuel with a serial number range from 188029 to 188914 should be removed from the parts stock. The above listed fuel injectors should be removed from the parts stock and the injectors should be held pending further instructions.
The valve housing may crack causing certain remanufactured fuel injectors to malfunction.Problem
Some remanufactured valve bodies on fuel injectors have been cracking under high pressure. This crack in the valve body can cause fuel to get into the engine oil.Solution
All 10R-0957 Injector Gp Fuel with serial number range 848368 to 850132 should be removed from the parts stock. 10R-0960 Injector Gp Fuel , 10R-0961 Injector Gp Fuel , 10R-0963 Injector Gp Fuel , and 10R-1268 Injector Gp Fuel with a serial number range from 188029 to 188914 should be removed from the parts stock. The above listed fuel injectors should be removed from the parts stock and the injectors should be held pending further instructions.