Information injection-pump assembly
BOSCH
9 400 619 598
9400619598
ZEXEL
101602-9763
1016029763
MITSUBISHI-HEAV
3436100022
3436100022
Rating:
Service parts 101602-9763 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
Include in #1:
101602-9763
as INJECTION-PUMP ASSEMBLY
Include in #2:
104742-1230
as _
Cross reference number
BOSCH
9 400 619 598
9400619598
ZEXEL
101602-9763
1016029763
MITSUBISHI-HEAV
3436100022
3436100022
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
1-5-3-6-
2-4
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 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.4
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
73.5
72.5
74.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.6+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
12
10.7
13.3
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
C
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
58
58
63
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=13 N1=900r/min N2=600r/min
----------
----------
K=13 N1=900r/min N2=600r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(20deg)+-5deg b=(3deg)+-5deg
----------
----------
a=(20deg)+-5deg b=(3deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-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 fuel injection lines 1. Remove bolt (1) and clamp (2) from the fuel injection nozzles to be removed.2. Install Tool (A) with the inside lip of the puller on the lower stepped diameter of the nozzle and the tip of the button in the threaded hole for bolt (1).
Do not exceed a torque of 17 N m (150 lb in) on the screw of Tool (A) during removal of the nozzle. Added force can cause the stem of the nozzle to bend or break off.
3. Tighten the screw of Tool (A) to a maximum torque of 17 N m (150 lb in) to remove fuel injection nozzle (3).4. If the fuel injection nozzle can not be removed with a maximum torque of 17 N m (150 lb in) on the screw of Tool (A), remove Tool (A).
Typical Example5. Remove the protective cap from fuel injection nozzle (3), and install Tool (B) as shown.
Hold Tool (B) so the center line of the tool is in alignment with the centerline of fuel injection nozzle (3). This will prevent distortion of the nozzle which can cause it to bend or break off during removal.
6. Remove the fuel injection nozzle with Tool (B).7. If Tool (B) was used to remove the fuel injection nozzle, replace the nozzle.8. If Tool (A) was used to remove the fuel injection nozzle, remove the carbon dam seal on the end of the nozzle.Install Fuel Injection Nozzle
1. Use Tool (C) to clean the bore for the fuel injection nozzle. Use an open end wrench or tap driver to turn Tool (C).2. Make reference to Special Instruction, Form No. SEHS7292, for the use of Tool (D). Clean the fuel injection nozzle with Tool (D). 3. Install a new seal (4) on fuel injection nozzle (3).4. Put carbon dam seal (5) on the small end of Tool (E). Expand the carbon dam seal by sliding it to the large end. Put Tool (E) against the fuel injection nozzle. Slide carbon dam seal (5) off Tool (E) on to the nozzle. Slide the carbon dam seal into position in the groove on the nozzle as shown. 5. Put fuel injection nozzle (3) in position in the cylinder head. Install clamp (2) and bolt (1) to hold the nozzle in position.End By:a. install fuel injection lines
Do not exceed a torque of 17 N m (150 lb in) on the screw of Tool (A) during removal of the nozzle. Added force can cause the stem of the nozzle to bend or break off.
3. Tighten the screw of Tool (A) to a maximum torque of 17 N m (150 lb in) to remove fuel injection nozzle (3).4. If the fuel injection nozzle can not be removed with a maximum torque of 17 N m (150 lb in) on the screw of Tool (A), remove Tool (A).
Typical Example5. Remove the protective cap from fuel injection nozzle (3), and install Tool (B) as shown.
Hold Tool (B) so the center line of the tool is in alignment with the centerline of fuel injection nozzle (3). This will prevent distortion of the nozzle which can cause it to bend or break off during removal.
6. Remove the fuel injection nozzle with Tool (B).7. If Tool (B) was used to remove the fuel injection nozzle, replace the nozzle.8. If Tool (A) was used to remove the fuel injection nozzle, remove the carbon dam seal on the end of the nozzle.Install Fuel Injection Nozzle
1. Use Tool (C) to clean the bore for the fuel injection nozzle. Use an open end wrench or tap driver to turn Tool (C).2. Make reference to Special Instruction, Form No. SEHS7292, for the use of Tool (D). Clean the fuel injection nozzle with Tool (D). 3. Install a new seal (4) on fuel injection nozzle (3).4. Put carbon dam seal (5) on the small end of Tool (E). Expand the carbon dam seal by sliding it to the large end. Put Tool (E) against the fuel injection nozzle. Slide carbon dam seal (5) off Tool (E) on to the nozzle. Slide the carbon dam seal into position in the groove on the nozzle as shown. 5. Put fuel injection nozzle (3) in position in the cylinder head. Install clamp (2) and bolt (1) to hold the nozzle in position.End By:a. install fuel injection lines