106671-1830 ZEXEL 9 400 619 690 BOSCH INJECTION-PUMP ASSEMBLY 9400619690 1066711830

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 690 9400619690

ZEXEL 106671-1830 1066711830

Service parts 106671-1830 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-7790

3. GOVERNOR 105489-4030

4. SUPPLY PUMP 105237-4480

5. AUTOM. ADVANCE MECHANIS 105636-2300

6. COUPLING PLATE 105663-0290

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6822

11. Nozzle and Holder 1-15300-303-2

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105030-4492

14. NOZZLE 105015-7050

15. NOZZLE SET

Include in #1:

106671-1830 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 690 9400619690

ZEXEL 106671-1830 1066711830

Zexel num

Bosch num

Firm num

Name

106671-1830
106671-1831

9 400 619 690

INJECTION-PUMP ASSEMBLY
* K

Calibration Data:

Adjustment conditions

Test oil
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 8-3-600

Overflow valve 134424-3920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 4.2 4.15 4.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 12

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 434 431 437

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 173.3 173.3

Boost pressure mmHg 1300 1300

Injection quantity adjustment_02

Adjusting point B

Rack position 4+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8 4.8 11.2

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point C

Rack position 8.3

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 225.5 222.5 228.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 8.3

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position (12)

Boost pressure kPa 149.3 149.3 149.3

Boost pressure mmHg 1120 1120 1120

Timer adjustment

Pump speed r/min 1050++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1050.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 1 1 1

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Deliver with the damper spring not operating. (5)Boost compensator excessive fuel lever setting: L1 (at boost pressure 0) (6)Boost compensator stroke: BCL (7)Main spring setting (8)Set idle sub-spring
----------
RT=1 TH=2.5mm L1=13.6+-0.1mm BCL=(3.7)+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=85.1mm
----------
a=72.5deg+-5deg b=15deg+-5deg

0000000901

F:Full load (1)Fix using the stopper bolt.
----------

----------
a=(19deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=32deg+-5deg b=64deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0.
----------
aa=13.6+-0.1mm
----------
a=(15deg) b=(15deg)

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(70deg)