Information injection-pump assembly
BOSCH
9 400 610 056
9400610056
ZEXEL
101401-1121
1014011121
Rating:
Service parts 101401-1121 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME017801
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 056
9400610056
ZEXEL
101401-1121
1014011121
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
131424-6220
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
1-3-4-2
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 1-3 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
-
Rack position
10.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
55.1
54.1
56.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.7+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
10
8.7
11.3
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
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
A
Rack position
R1(10.6)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
55.1
54.1
56.1
Basic
*
Fixing the lever
*
Boost pressure
kPa
42.7
42.7
Boost pressure
mmHg
320
320
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.3
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
71
67
75
Fixing the lever
*
Boost pressure
kPa
42.7
42.7
Boost pressure
mmHg
320
320
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-0.
4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
39.9
35.9
43.9
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2+0.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
35.7
31.7
39.7
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
67
67
72
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R1-0.4
Boost pressure
kPa
22.7
21.4
24
Boost pressure
mmHg
170
160
180
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
R1(10.6)
Boost pressure
kPa
36
29.3
36
Boost pressure
mmHg
270
220
270
Timer adjustment
Pump speed
r/min
1450
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_02
Pump speed
r/min
1700
Advance angle
deg.
3.5
3
4
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
T1=B88 BCL=0.4+-0.1mm
----------
----------
T1=B88 BCL=0.4+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=40mm
----------
a=26deg+-5deg b=42deg+-3deg
----------
aa=40mm
----------
a=26deg+-5deg b=42deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Free (at shipping)
(2)Use the hole at R = aa
(3)Rack position corresponding to bb
(4)Set the stopper bolt so that speed = cc and rack position = dd. After setting the stopper bolt, confirm non-injection at speed = ee (rack position = ff or less).
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=11deg
----------
a=(130deg)
----------
aa=11deg
----------
a=(130deg)
Information:
(1) Tension of brush spring ... 80 to 90 oz.(2.27 to 2.55 kg)(2) Torque for bolts ... 8 lb. ft.(1.11 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)(4) Clearance for the pinion ... .020 to .050 in.(0.51 to 1.27 mm)2P6162 24V (Prestolite Number MES 6301 K) 3P110 24V (Prestolite Number MFY 6401 I)
Rotation is clockwise when seen from drive end.Minimum speed with no load ... 5000 rpmCurrent consumption (draw) with no load: Maximum at 20 V ... 77 A(1) Tension of brush spring ... 80 to 90 oz.(2.27 to 2.55 kg)(2) Torque for housing bolts ... 8 lb. ft.(1.11 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)(4) Clearance between pinion and housing (pinion clearance) ... .020 to .050 in.(0.51 to 1.27 mm)2P2502 24V (Delco-Remy Number 1113393)
Rotation is clockwise when seen from drive end. Minimum speed with no load ... 5500 rpmMaximum speed with no load ... 7500 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 20 V ... 92.5 AMaximum with solenoid at 20 V ... 120.1 AClearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm) (1) Tension of brush spring* ... 36 to 40 oz.(1.01 to 1.14 kg)(2) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg) ... 80 oz.(2.27 kg)*Minimum for leaf springs 4N3182 24V (Delco-Remy Number 1114711)
Rotation is clockwise when seen from drive end.Minimum speed with no load ... 5500 rpmMaximum speed with no load ... 7500 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 20V ... 108.5 AMaximum with solenoid at 20V ... 135.1 AClearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm) (1) Tension of brush spring ... 80 oz.(2.26 kg)(2) Torque for screws holding nose housing to lever housing ... 13 to 17 lb. ft.(1.8 to 2.4 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)
Rotation is clockwise when seen from drive end.Minimum speed with no load ... 5000 rpmCurrent consumption (draw) with no load: Maximum at 20 V ... 77 A(1) Tension of brush spring ... 80 to 90 oz.(2.27 to 2.55 kg)(2) Torque for housing bolts ... 8 lb. ft.(1.11 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)(4) Clearance between pinion and housing (pinion clearance) ... .020 to .050 in.(0.51 to 1.27 mm)2P2502 24V (Delco-Remy Number 1113393)
Rotation is clockwise when seen from drive end. Minimum speed with no load ... 5500 rpmMaximum speed with no load ... 7500 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 20 V ... 92.5 AMaximum with solenoid at 20 V ... 120.1 AClearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm) (1) Tension of brush spring* ... 36 to 40 oz.(1.01 to 1.14 kg)(2) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg) ... 80 oz.(2.27 kg)*Minimum for leaf springs 4N3182 24V (Delco-Remy Number 1114711)
Rotation is clockwise when seen from drive end.Minimum speed with no load ... 5500 rpmMaximum speed with no load ... 7500 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 20V ... 108.5 AMaximum with solenoid at 20V ... 135.1 AClearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm) (1) Tension of brush spring ... 80 oz.(2.26 kg)(2) Torque for screws holding nose housing to lever housing ... 13 to 17 lb. ft.(1.8 to 2.4 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)