Rating:
Information injection-pump assembly
BOSCH
9 400 619 649
9400619649
ZEXEL
101493-9080
1014939080
Service parts 101493-9080 INJECTION-PUMP ASSEMBLY:
1.
_
4.
SUPPLY PUMP
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
SLH113H50
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 619 649
9400619649
ZEXEL
101493-9080
1014939080
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
2.8
2.75
2.85
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
11.7
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
57.1
56.6
57.6
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
9.4+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
9
7
11
Max. variation between cylinders
%
0
-14
14
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(11.7)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
57.1
56.6
57.6
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.1
Pump speed
r/min
1700
1700
1700
Average injection quantity
mm3/st.
67.5
63.5
71.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.25
Pump speed
r/min
625
625
625
Average injection quantity
mm3/st.
39.8
35.8
43.8
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
91
81
96
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
H
Rack position
9.3+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
7
6.5
7.5
Fixing the lever
*
Remarks
Set lever at delivery.
Set lever at delivery.
Timer adjustment
Pump speed
r/min
1350+-25
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1620
Advance angle
deg.
2.5
2.2
2.8
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
----------
T1=G19
----------
----------
T1=G19
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H' (rack position = bb, speed = cc)
----------
aa=36mm bb=(9.3)mm cc=325r/min
----------
a=20deg+-5deg b=(39deg)+-3deg
----------
aa=36mm bb=(9.3)mm cc=325r/min
----------
a=20deg+-5deg b=(39deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=(30deg)+-5deg
----------
aa=39mm
----------
a=14deg+-5deg b=(30deg)+-5deg
0000001501 LEVER
CL:Center line of camshaft
ST:Stop adjuster screw
f1:Direction for pulling the speed lever
f2:Direction for pulling the stop lever
1. Stop lever adjustment outline
(1)After completing all adjustments, confirm that the lever angle is within the specifications in the normal position.
(2)Set the speed lever in the full speed position.
(3)At pump speed Na, position the rack at non-injection position Ra.
(4)Set the stop adjusting screw to fix the speed lever in the idling position.
(5)Confirm that there is no injection at pump speed Nb.
----------
Na=1820r/min Nb=325r/min Ra=4.6+-0.3mm
----------
----------
Na=1820r/min Nb=325r/min Ra=4.6+-0.3mm
----------
0000001601 ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
(D) Cover
1. Aneroid compensator unit adjustment
(1)Select the push rod 2 to obtain L2.
(2)Screw in (A) to obtain L1.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
(3)As there is hysterisis, measure when the absolute pressure drops.
(4)Hysterisis must not exceed rack position = h1.
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=-
----------
Ra=R1(11.7)mm Rb=R1-0.41mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=57.1+-0.5cm3/1000st Q2=(52.1)+-1cm3/1000st
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=-
----------
Ra=R1(11.7)mm Rb=R1-0.41mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=57.1+-0.5cm3/1000st Q2=(52.1)+-1cm3/1000st
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=15deg
----------
a=(130deg)
----------
aa=15deg
----------
a=(130deg)