Information injection-pump assembly
BOSCH
9 400 617 500
9400617500
ZEXEL
106681-4224
1066814224
Rating:
Cross reference number
BOSCH
9 400 617 500
9400617500
ZEXEL
106681-4224
1066814224
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
2.8
2.75
2.85
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
A
Rack position
11.2
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
303
294
312
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
107
107
Boost pressure
mmHg
805
805
Remarks
Injection at all cylinders.
Injection at all cylinders.
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.6+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
26
23
29
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Injection only at cylinders 1, 3, 4 and 6.
Injection only at cylinders 1, 3, 4 and 6.
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
260
260
280
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-2.5
Boost pressure
kPa
55.3
48.6
62
Boost pressure
mmHg
415
365
465
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(11.2)
Boost pressure
kPa
98
95.3
100.7
Boost pressure
mmHg
735
715
755
Timer adjustment
Pump speed
r/min
450--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
400
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
700
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)The torque control spring does not operate.
(4)RACK LIMIT
(5)Boost compensator stroke: BCL
(6)Idle sub spring setting: L1.
----------
K=25 BCL=2.5+-0.1mm L1=5-0.5mm
----------
----------
K=25 BCL=2.5+-0.1mm L1=5-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(20deg)+-5deg b=(29deg)+-5deg
----------
----------
a=(20deg)+-5deg b=(29deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa, rack position bb
(2)Seal at delivery.
----------
aa=0r/min bb=3-0.5mm
----------
a=27deg+-5deg b=62.5deg+-5deg
----------
aa=0r/min bb=3-0.5mm
----------
a=27deg+-5deg b=62.5deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(20deg)
----------
----------
a=(20deg)
Information:
(1) 7S7144 Spring for valves (new): Length under test force ... 1.766 in.(44.86 mm)Test force ... 57.7 4.5 lb.(257 20 N)Use again minimum load at length under test force ... 46.5 lb.(207 N)Length of spring at valve open position ... 1.271 in.(32.28 mm)Use again minimum load at valve open position ... 144 lb.(640 N)Free length after test ... 2.05 in.(52.1 mm)Outside diameter ... 1.386 in.(35.20 mm)Spring must not be bent more than ... .072 in.(1.83 mm)(2) Height to top of valve guide ... .875 in.(22.23 mm)(3) Diameter of valve stem (new) ... .3717 .0003 in.(9.441 0.008 mm) Use again minimum diameter ... .3704 in.(9.408 mm)Bore in valve guide with guide installed in the head (new) ... .3733 .0010 in.(9.482 0.025 mm)Maximum permissible bore (worn) ... .3771 in.(9.578 mm)(4) Valve lip thickness: 8N875 Exhaust ValveUse again minimum ... .106 in.(2.69 mm)7S8809 Intake ValveUse again minimum ... .106 in.(2.69 mm)(5) Diameter of valve head: Exhaust valve ... 1.896 .005 in.(48.16 0.13 mm)Intake valve ... 2.020 .005 in.(51.31 0.13 mm)(6) Angle of valve face ... 291/4° (7) Depth of bore in head for valve seat insert: Exhaust (5S7221) ... .449 .005 in.(11.40 0.13 mm)Intake Earlier (5S7218) ... .449 .005 in.(11.40 0.13 mm)Later (7N4448) ... .349 .005 in.(8.86 0.13 mm)(8) Diameter of valve seat insert: Exhaust (5S7221) ... 2.0035 .0005 in.(50.889 0.013 mm)Intake Earlier (5S7218) ... 2.1285 .0005 in.(54.064 0.013 mm)Later (7N4448) ... 2.0485 .0005 in.(52.032 0.013 mm)Bore in head for valve seat insert:Exhaust (5S7221) ... 2.0005 .0005 in.(50.813 0.013 mm)Intake Earlier (5S7218) ... 2.1255 .0005 in.(53.988 0.013 mm)Later (7N4448) ... 2.0457 .0005 in.(51.961 0.013 mm)(9) Angle of face of valve seat insert ... 30°(10) Maximum permissible width of valve seat (intake and exhaust) ... .076 in.(1.93 mm) Minimum permissible width of valve seat (intake and exhaust) ... .045 in.(1.14 mm)(11) Dimension from top of closed valve to face of head: Maximum permissible dimension for 8N875 Exhaust Valve ... .163 in.(4.14 mm)Minimum permissible dimension for 8N875 Exhaust Valve ... .079 in.(2.01 mm)Maximum permissible dimension for 7S8809 Intake Valve ... .140 in.(3.56 mm)Minimum permissible dimension for 7S8809 Intake Valve ... .066 in.(1.68 mm)(12) Outside diameter of the face of the valve seat or valve seat insert: Exhaust seat ... 1.810 in.(45.97 mm)Maximum permissible exhaust seat ... 1.860 in.(47.24 mm)Intake seat ... 1.934 in.(49.12 mm)Maximum permissible, intake seat ... 1.984 in.(50.39 mm)(13) Angle to grind seat face of the insert to get a reduction of maximum seat diameter ... 15°