Information injection-pump assembly
BOSCH
9 400 612 745
9400612745
ZEXEL
101495-3442
1014953442
Rating:
Service parts 101495-3442 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
Cross reference number
BOSCH
9 400 612 745
9400612745
ZEXEL
101495-3442
1014953442
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
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
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
10.8
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
74.5
73.5
75.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.5+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
12.5
11.5
13.5
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
----------
K=17
----------
----------
K=17
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=60mm
----------
a=25deg+-5deg b=32deg+-5deg
----------
aa=60mm
----------
a=25deg+-5deg b=32deg+-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)
0000001501 I/P WITH LOAD PLUNGER ADJ
Load plunger-equipped pump adjustment
1. Adjust the variation between cylinders and the injection quantity.
2. At Full point A, adjust the pre-stroke to the specified value.
3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
----------
----------
----------
----------
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)After adjusting the injection quantity, adjust at rack position aa.
(5)-
----------
aa=10.8mm
----------
a=58deg+-3deg b=2deg+-30min
----------
aa=10.8mm
----------
a=58deg+-3deg b=2deg+-30min
Information:
Illustration 1 g06045444
Typical example
Illustration 2 g03821967
Typical example
(3) Existing fuel injection pump
(4) Existing advance boxA new fuel injection pump (1) has been introduced. The new fuel injection pump has an improved design of advance box (2) that is more robust against air in fuel.Adaptable To: New 483-2326 Fuel Injection Pump replaces 462-8111 Fuel Injection PumpNew 483-2329 Fuel Injection Pump replaces 248-2366 Fuel Injection Pump.To remove the existing fuel injection pump, refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure.To install a new fuel injection pump, refer to Disassembly and Assembly, "Fuel Injection Pump - Install" for the correct procedure.Ensure that the fuel system is primed. Refer to Service Magazine, SEPD1541, "Alternative Fuel System Prime Procedure for 3054C, C4.4 (Mech), and C3.3 Machine Engines with a Delphi Fuel Injection Pump Installed".