Rating:
Information injection-pump assembly
BOSCH
9 400 612 499
9400612499
ZEXEL
101609-3620
1016093620
Service parts 101609-3620 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
4063212
12.
Open Pre:MPa(Kqf/cm2)
22.0{224}
15.
NOZZLE SET
Include in #1:
101609-3620
as INJECTION-PUMP ASSEMBLY
Include in #2:
104266-1130
as _
Cross reference number
BOSCH
9 400 612 499
9400612499
ZEXEL
101609-3620
1016093620
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
131424-3420
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
2.45
2.4
2.5
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
12.4
Pump speed
r/min
1025
1025
1025
Average injection quantity
mm3/st.
130.5
129.5
131.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
56
56
Boost pressure
mmHg
420
420
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.8+-0.5
Pump speed
r/min
525
525
525
Average injection quantity
mm3/st.
9.5
8.5
10.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
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
E
Rack position
13++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
110
110
120
Fixing the lever
*
Boost pressure
kPa
56
56
Boost pressure
mmHg
420
420
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
850
850
850
Rack position
R1-1.9
Boost pressure
kPa
29.3
29.3
29.3
Boost pressure
mmHg
220
220
220
Boost compensator adjustment_02
Pump speed
r/min
850
850
850
Rack position
R1-1.3
Boost pressure
kPa
32
30.7
33.3
Boost pressure
mmHg
240
230
250
Boost compensator adjustment_03
Pump speed
r/min
850
850
850
Rack position
R1(12.4)
Boost pressure
kPa
42.7
42.7
42.7
Boost pressure
mmHg
320
320
320
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)It is not necessary to supply hydraulic pressure because the specification is for the hydraulic ACT normally ON.
(4)RACK LIMIT
(5)Boost compensator stroke: BCL
----------
K=13 BCL=1.9+-0.1mm
----------
----------
K=13 BCL=1.9+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)At hole at R = aa (center)
(2)Rack position = bb, speed = cc
----------
aa=77mm bb=1-0.5mm cc=0r/min
----------
a=(10deg)+-5deg b=31deg+-3deg c=(30deg)+-5deg
----------
aa=77mm bb=1-0.5mm cc=0r/min
----------
a=(10deg)+-5deg b=31deg+-3deg c=(30deg)+-5deg
Timing setting
(1)Pump vertical direction
(2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa).
(3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery).
(4)B.T.D.C.: aa
(5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut.
(6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft.
(7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=13deg bb=0deg
----------
a=54deg36min+-3deg b=6deg30min+-30min
----------
aa=13deg bb=0deg
----------
a=54deg36min+-3deg b=6deg30min+-30min