Information injection-pump assembly
BOSCH
9 400 611 349
9400611349
ZEXEL
106871-9330
1068719330

Rating:
Service parts 106871-9330 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
106871-9330
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 349
9400611349
ZEXEL
106871-9330
1068719330
Zexel num
Bosch num
Firm num
Name
106871-9330
9 400 611 349
DPICO
INJECTION-PUMP ASSEMBLY
P Q
P Q
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
134424-1320
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
1-2-7-3-
4-5-6-8
Pre-stroke
mm
4.8
4.75
4.85
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
10.3
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
130
126.1
133.9
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.4+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
19
16.1
21.9
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.3)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
130
129
131
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R2(R1+0.
8)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
143
139
147
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
155
115
195
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
(N4+50)-
-
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
N4(800)
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
(1100)
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Excess fuel setting for starting: SXL
(3)Damper spring setting
----------
SXL=(R2+0.2)+0.2mm
----------
----------
SXL=(R2+0.2)+0.2mm
----------
Speed control lever angle

F:Full speed
----------
----------
a=(19.5deg)+-5deg
----------
----------
a=(19.5deg)+-5deg
0000000901

F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=30.5deg+-3deg
----------
----------
a=10deg+-5deg b=30.5deg+-3deg
Stop lever angle

S:Stop the pump.
(1)Rack position = [(non-injection rack at speed = aa)-0.3]-0.5
(2)Stopper bolt setting
(3)Free (at delivery)
(4)Drive side
(5)(Actual measurement)
----------
aa=1320r/min
----------
a=10.5deg+-5deg
----------
aa=1320r/min
----------
a=10.5deg+-5deg
0000001501 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=4.9+-0.1mm
----------
----------
N1=325r/min Ra=4.9+-0.1mm
----------
0000001601 GOVERNOR TORQUE CONTROL

Dr:Torque control stroke
(A): Without torque control spring capsule
1. Adjustment procedures
(1)Procedure is the same as that for the RFD (former type), except that the positive torque control stroke must be determined at the full lever setting.
2. Procedures for adjustment
(1)Remove the torque control spring capsule.
(2)Operate the pump at approximately N1. (End of idling spring operation < N1.)
(3)Tilt the lever to the full side.
(4)Set so that R = RF.
(5)Increase the speed by pushing in the screw (attached to the bracket on the rear of the tension lever) through the adjusting window.
(6)Adjust so that the torque control stroke Dr1 can be obtained.
(7)Align N2 and N3 with the torque control spring capsule.
3. Final confirmation
(1)After final confirmation, temporarily set the load lever to N = N1, R = idling position.
(2)From this condition, increase speed to N = N4.
(3)Confirm that positive torque control stroke is Dr2.
----------
N1=500r/min N2=(585)r/min N3=(1070)r/min N4=1100r/min RF=10.1mm Dr1=1mm Dr2=0+0.3mm
----------
----------
N1=500r/min N2=(585)r/min N3=(1070)r/min N4=1100r/min RF=10.1mm Dr1=1mm Dr2=0+0.3mm
----------
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=13deg
----------
a=(40deg)
----------
aa=13deg
----------
a=(40deg)
Information:
The problems in this section are problems that do come about and are normally called "low power." These problems are not necessarily more common than engine problems, but they are possible problems which you need to read and check before an engine is disassembled.Read all of the items but make sure the first three are checked completely before making any engine test.Possible Causes/Corrections
Tachometer Error/To check, connect a tachometer of known accuracy to the engine. Run the engine and make a comparison of the readings of the vehicle and test tachometers. If vehicle tachometer is bad, make repairs as necessary or install a new tachometer. Engine Operated at High Altitude/Less oxygen at higher altitudes causes the engine horsepower to go down. There is no effect on the horsepower of the engine for the first 2280 m (7500 ft.) above sea level of operation. Brakes Do Not Completely Release/Check the brakes by feeling all the brake drums. If the brakes of a wheel do not completely release, the brake drum for that wheel will be hotter than the brake drums for the other wheels. With the truck lifted with a jack, the wheels must have free rotation when turned by hand. Extra Engine Driven Equipment/Air compressors, hydraulic pumps, alternator, and other engine driven equipment that has damage, or that was not installed correctly, or that is not in correct adjustment, can take more horsepower to drive than expected. If necessary, disconnect the equipment and test the engine. Speedometer Error/A bad speedometer does not give the correct speed or the correct indication of fuel consumption. An indication of low speed can cause the operator to feel that he has a power problem. Speeds Too High/The need for more horsepower is easy to see as the speed of the vehicle is increased. This is especially true if the front of the vehicle has a large surface area. Application personnel can give you the horsepower necessary for different vehicle designs at different speeds. Overload on Vehicle/Application personnel can give you the horsepower needs for different vehicles. High Moving Resistance/Soft ground conditions cause a need for more horsepower. To see if the problem is the engine, test the vehicle on a surface known to be good, or test on a chassis dynamometer. High Wind Resistance/The horsepower needs for a truck can be divided into two parts. Part of the horsepower is used to move the vehicle and part is used to get through the resistance of the wind. The horsepower necessary to get through the resistance of the wind will increase as the vehicle is used at higher speeds. Vehicles with large front area have a higher wind resistance and take more horsepower than those with a small front area. Some types of trucks, for example those used for the transportation of automobiles and/or boats have high wind resistance even if the front area is small. Moving against the wind has the same effect on wind resistance as does higher vehicle speed. Power Loss
Tachometer Error/To check, connect a tachometer of known accuracy to the engine. Run the engine and make a comparison of the readings of the vehicle and test tachometers. If vehicle tachometer is bad, make repairs as necessary or install a new tachometer. Engine Operated at High Altitude/Less oxygen at higher altitudes causes the engine horsepower to go down. There is no effect on the horsepower of the engine for the first 2280 m (7500 ft.) above sea level of operation. Brakes Do Not Completely Release/Check the brakes by feeling all the brake drums. If the brakes of a wheel do not completely release, the brake drum for that wheel will be hotter than the brake drums for the other wheels. With the truck lifted with a jack, the wheels must have free rotation when turned by hand. Extra Engine Driven Equipment/Air compressors, hydraulic pumps, alternator, and other engine driven equipment that has damage, or that was not installed correctly, or that is not in correct adjustment, can take more horsepower to drive than expected. If necessary, disconnect the equipment and test the engine. Speedometer Error/A bad speedometer does not give the correct speed or the correct indication of fuel consumption. An indication of low speed can cause the operator to feel that he has a power problem. Speeds Too High/The need for more horsepower is easy to see as the speed of the vehicle is increased. This is especially true if the front of the vehicle has a large surface area. Application personnel can give you the horsepower necessary for different vehicle designs at different speeds. Overload on Vehicle/Application personnel can give you the horsepower needs for different vehicles. High Moving Resistance/Soft ground conditions cause a need for more horsepower. To see if the problem is the engine, test the vehicle on a surface known to be good, or test on a chassis dynamometer. High Wind Resistance/The horsepower needs for a truck can be divided into two parts. Part of the horsepower is used to move the vehicle and part is used to get through the resistance of the wind. The horsepower necessary to get through the resistance of the wind will increase as the vehicle is used at higher speeds. Vehicles with large front area have a higher wind resistance and take more horsepower than those with a small front area. Some types of trucks, for example those used for the transportation of automobiles and/or boats have high wind resistance even if the front area is small. Moving against the wind has the same effect on wind resistance as does higher vehicle speed. Power Loss
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Dpico
106871-9330
9 400 611 349
INJECTION-PUMP ASSEMBLY
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