Rating:
Information injection-pump assembly
BOSCH
9 400 612 534
9400612534
ZEXEL
101607-1790
1016071790
Service parts 101607-1790 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME056371
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 612 534
9400612534
ZEXEL
101607-1790
1016071790
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
131424-5120
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
4.5
4.45
4.55
Beginning of injection position
Governor side NO.1
Governor 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
-
Rack position
9.6
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
112
108.6
115.4
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
8+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
18.5
15.7
21.3
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(9.6)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
112
111
113
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(9.6)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
113.5
111
116
Difference in delivery
mm3/st.
9
9
9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
120
160
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
850--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
0.9
0.4
1.4
Timer adjustment_04
Pump speed
r/min
1150
Advance angle
deg.
3
2.5
3.5
Timer adjustment_05
Pump speed
r/min
-
Advance angle
deg.
4
4
5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Excess fuel setting for starting: SXL
(5)Damper spring setting
(6)Set at delivery
----------
RT=1 TH=2.7mm SXL=R1+0.2mm
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RT=1 TH=2.7mm SXL=R1+0.2mm
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Speed control lever angle
F:Full speed
----------
----------
a=(15deg)+-5deg
----------
----------
a=(15deg)+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=24deg+-5deg b=27.5deg+-3deg
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a=24deg+-5deg b=27.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, stopper bolt setting
(2)Rack position bb
(3)Free (at delivery)
----------
aa=5.5-0.5mm bb=16mm
----------
a=12.5deg+5deg-7deg b=34deg+-5deg c=(66.5deg)
----------
aa=5.5-0.5mm bb=16mm
----------
a=12.5deg+5deg-7deg b=34deg+-5deg c=(66.5deg)
0000001501 TAMPER PROOF
N:Pump speed (r/min)
R:Rack position (mm)
S:Shim thickness (1; mm)
L:Lever angle (deg)
T:Thickness (mm)
P/N: part number of shim
(A) Speed set bolt
Locknut B
Speed set bolt C
(d) Shim
(E) Screw
Tamper proof adjustment
(1)Adjustment standard
1. Tamperproof adjustment specifications are shown in figure 1.
(2)Adjustment procedure
1. Temporarily set with 4 shims (D; thickness = 0.4 mm) assembled.
2. Perform governor adjustment as described in the calibration data sheet.
3. At this time, confirm that the specified setting (point Y: 1165 r/min) can be obtained using the speed set bolt (A).
4-1 When specified setting can be obtained
4-1-1 Back off the speed set bolt (C).
4-1-2 Confirm that point X is satisfied when the speed set bolt (A) is further tightened.
4-2 When specified setting can be obtained
4-2-1 Repeat disassembly and confirm that the specified setting (point Y: 1165 r/min) can be obtained when a suitable number of shims (D) are removed.
4-2-2 As in 4-1 above, confirm that the point X is satisfied when the setting is increased.
4-2-3 Adjust after referring to figure 2 for the number of shims.
Reference: Screw (E) and the pump housing contact in 4-1 and 4-2 above.
5-1 After completing confirmation in (1), reset at the specified setting (point Y: 1165 r/min) using the speed set bolt (A) and (C).
5-2 fix using locknut (B) and finish adjustment.
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0000001601 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325r/min Ra=7.3+-0.1mm
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----------
N1=325r/min Ra=7.3+-0.1mm
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Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(7deg)
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----------
a=(7deg)