Information injection-pump assembly
BOSCH
9 400 611 539
9400611539
ZEXEL
106682-9423
1066829423
Rating:
Service parts 106682-9423 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6212-12-3200
12.
Open Pre:MPa(Kqf/cm2)
24.5{250}
15.
NOZZLE SET
Include in #1:
106682-9423
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 539
9400611539
ZEXEL
106682-9423
1066829423
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
131425-1620
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
3.3
3.25
3.35
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
12.8
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
339
334
344
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
101
101
Boost pressure
mmHg
760
760
Injection quantity adjustment_02
Adjusting point
C
Rack position
7.6+-0.5
Pump speed
r/min
415
415
415
Average injection quantity
mm3/st.
17
15.5
18.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
285
275
295
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
(R1)-2
Boost pressure
kPa
32
25.3
38.7
Boost pressure
mmHg
240
190
290
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
(R1)
Boost pressure
kPa
68
65.3
70.7
Boost pressure
mmHg
510
490
530
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)Deliver without the torque control spring operating.
(4)Before adjusting the governor, adjust the idle sub-spring.
(5)RACK LIMIT
(6)Boost compensator stroke
----------
K=18
----------
----------
K=18
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Stopper bolt setting
----------
----------
a=20deg+-5deg b=27deg+-5deg c=45deg+-5deg
----------
----------
a=20deg+-5deg b=27deg+-5deg c=45deg+-5deg
0000001501 GOVERNOR IDLE SUB SPRING
f : Installation load ON
2 stage idle sub-spring simultaneous setting method
1. (1) Remove the idling sub spring capsule from the governor.
(2)Tighten the screw (A) until it contacts the spring (B) (that is, until the set force is generated).
(3)Return to speed N1.
(4)Set so that the set force is zero.
(5)Fix using the lock nut (C).
2. Set the idle sub spring capsule adjusted as per (1) 1.
(2)Same as the normal 1 stage idle sub spring.
(3)Set so that it satisfies the governor adjustment standards.
(4)Do not loosen lock nut (C) at this time.
----------
N1=1/2
----------
----------
N1=1/2
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(10deg)
----------
----------
a=(10deg)
Information:
1. Drain the coolant and oil from the engine.2. Remove bolt (1) and retainer (2) that hold the oil lines in the BrakeSaver control valve. 3. Disconnect oil lines (3) and (4) from the oil cooler. Remove oil lines (3) and (4) from the BrakeSaver control valve.4. Fasten a hoist to the oil cooler. 5. Remove two bolts (8) to disconnect elbow (10) from front bonnet (9). Remove two bolts (7) to disconnect front bonnet (9) from the water pump.6. Remove four bolts (5) to disconnect the rear bonnet from the cylinder block. Disconnect bracket (12).7. Remove oil cooler (11), front bonnet (9) and rear bonnet (6) from the engine as a unit. The weight is approximately 54 kg (120 lb.).8. Make a separation of front bonnet (9) and rear bonnet (6) from oil cooler (11). 9. Clean oil cooler core tubes (13) with a 3.81 mm (.150 in.) diameter rod.10. Inspect all O-ring seals and gaskets for damage, and make replacements if needed. Put clean engine oil on the O-ring seals.11. Install rear bonnet (6) and front bonnet (9) on oil cooler (11).12. Fasten a hoist, and put the oil cooler and bonnets as a unit in place on the engine. Connect bracket (12) but do not tighten the bolts at this time.13. Install the gasket and four bolts (5) that hold rear bonnet (6) to the engine block. Do not tighten the bolts at this time.14. Install the gasket and two bolts (7) that hold front bonnet (9) to the water pump. Do not tighten the bolts at this time.15. Install the gasket and bolts (8) that hold elbow (10) to the front bonnet. Tighten all the bolts.16. Make sure the O-ring seals are in place on the oil lines, and install oil lines (3) and (4).17. Install retainer (2) to hold the oil lines in the BrakeSaver control valve. If the bottom plug in the oil pan was removed, put the split (seam) of the gasket for the plug against the oil pan. If either plug on the side of the oil pan was removed, put 5P3413 Thread Sealant With Teflon on the threads, and tighten the plug to a torque of 80 11 N m (60 8 lb.ft.).18. Fill the engine with coolant and oil. See the Maintenance Manual.