Information injection-pump assembly
BOSCH
9 400 613 307
9400613307
ZEXEL
106691-4112
1066914112
Rating:
Service parts 106691-4112 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
27.5{280}
15.
NOZZLE SET
Include in #1:
106691-4112
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 613 307
9400613307
ZEXEL
106691-4112
1066914112
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-4120
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)
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
3.75
3.7
3.8
Rack position
Point A or more. R=A++
Point A or more. R=A++
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
11.7
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
137.5
135.5
139.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
37.3
37.3
Boost pressure
mmHg
280
280
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.5+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
21
19.5
22.5
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
11.9++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
160
150
170
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
10.1
Boost pressure
kPa
8
6.7
9.3
Boost pressure
mmHg
60
50
70
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
11.15
Boost pressure
kPa
24
24
24
Boost pressure
mmHg
180
180
180
Timer adjustment
Pump speed
r/min
(N1+50)-
-
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
N1
Advance angle
deg.
0.5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
2
1.7
2.3
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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)RACK LIMIT
(4)Boost compensator stroke
(5)Set idle sub-spring
(6)Main spring setting
(7)Rack difference between N = N1 and N = N2
----------
K=16 N1=1000r/min N2=500r/min
----------
----------
K=16 N1=1000r/min N2=500r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=69mm
----------
a=(9deg)+-5deg b=(28deg)+-5deg
----------
aa=69mm
----------
a=(9deg)+-5deg b=(28deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, speed = bb.
(2)Normal
----------
aa=1-0.5mm bb=0r/min
----------
a=33deg+-5deg b=70deg+-5deg
----------
aa=1-0.5mm bb=0r/min
----------
a=33deg+-5deg b=70deg+-5deg
0000001501 TAMPER PROOF
Tamperproofing-equipped boost compensator cover installation procedure
(A) After adjusting the boost compensator, tighten the bolts to remove the heads.
(1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=8deg
----------
a=(140deg)
----------
aa=8deg
----------
a=(140deg)
Information:
Table 9
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $01 CCM is the sending module
3 $25 IID 25
4 $07 Number of bytes
5 $58 GSC number 1
6, 7 $00 $82 PID $0082 GSC Fault Log Codes, Status, And Number of occurrences
8, 9 $00 $BE CID 190 (engine speed sensor fault)
10 $C3 Count included, inactive fault, logged fault, standard FMI (3)
11 $04 Occurrence count of 4
12 $24 Checksum
IID 00 is used to request additional information on a fault 500000070058008300BEC34DIID 00 - Special parameter Command
Table 10
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $01 CCM is the sending module
3 $00 IID 00
4 $07 Number of bytes
5 $00 Reply in ASCII format
6 $58 GSC number 1
7, 8 $00 $83 PID $0083 GSC Fault Log Request For Additional Data
9, 10, 11 $00 $BE $C3 More information requested on CID 190 FMI 3
12 $4D Checksum
IID 25 will contain the reply as PID $0084 5001250B58008400BEC303000C001102IID 25 - Single Parameter Read Response
Table 11
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $01 CCM is the sending module
3 $25 IID 25
4 $0B Number of bytes
5 $58 GSC number 1
6, 7 $00 $84 PID $0084 GSC Fault Log Response For Additional Data
8, 9 $00 $BE CID 190
10 $C3 More information on FMI 3
11 $03 Three occurrences of this fault
12, 13 $00 $0C First occurrence at 12 hours
14, 15 $00 $11 Last occurrence at 17 hours
16 $02 Checksum Monitoring Generator Phase
The following example shows how to select which generator phase the GSC monitors.
Use IID 34 to write the parameters of PID $F0B0: 500034050048F0B0007FIID 34 - Single Parameter Write Request
Table 12
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $00 User's PC is the sending module
3 $34 IID 34
4 $05 Number of bytes
5 $00 Reply in ASCII format
6 $58 GSC number 1
7, 8 $F0 $B0 PID $F0B0 Generator Phase Select
9 $00 Phase A-B Voltage, Phase A Current
10 $7F Checksum
IID 35 is the response from the CCM: 5001350458F0B0007EIID 35 - Single Parameter Write Response
Table