101607-1790 ZEXEL 9 400 612 534 BOSCH INJECTION-PUMP ASSEMBLY 9400612534 1016071790


101607-1790 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 612 534 9400612534
ZEXEL 101607-1790 1016071790

Service parts 101607-1790 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4051
3. GOVERNOR 105490-5650
4. SUPPLY PUMP 105210-4790
5. AUTOM. ADVANCE MECHANIS 105614-4100
6. COUPLING PLATE 105662-0590
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6021
11. Nozzle and Holder ME056371
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105030-5010
14. NOZZLE 105015-5390
15. NOZZLE SET

Include in #1:

101607-1790 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 534 9400612534
ZEXEL 101607-1790 1016071790


Zexel num
Bosch num
Firm num
Name
101607-1790 
101607-1791 
9 400 612 534 
   
INJECTION-PUMP ASSEMBLY
6D22 * K 14BF PE6AD PE

Calibration Data:

Adjustment conditions
Test oil
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
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
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
Difference between angles 1
Cal 1-5
deg.   60 59.5 60.5
Difference between angles 2
Cal 1-3
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cyl.1-2
deg.   240 239.5 240.5
Difference between angles 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
 
Timer adjustment
Pump speed r/min   850--
Advance angle deg.   0 0 0
Remarks
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
 

Test data Ex:

Governor adjustment

Test data 101607-1790
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
----------

Speed control lever angle

Test data 101607-1790
F:Full speed
----------

----------
a=(15deg)+-5deg

0000000901

Test data 101607-1790
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=24deg+-5deg b=27.5deg+-3deg

Stop lever angle

Test data 101607-1790
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)

0000001501 TAMPER PROOF

Test data 101607-1790
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.
----------

----------

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
----------

Timing setting

Test data 101607-1790
(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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