106671-5081 ZEXEL 9 400 619 691 BOSCH INJECTION-PUMP ASSEMBLY 9400619691 1066715081


106671-5081 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 619 691 9400619691
ZEXEL 106671-5081 1066715081

Service parts 106671-5081 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106061-7220
3. GOVERNOR 105487-5290
4. SUPPLY PUMP 105217-1750
5. AUTOM. ADVANCE MECHANIS 105636-2160
6. COUPLING PLATE 105663-0650
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-7030
11. Nozzle and Holder 1660096573
12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.6{230}.
13. NOZZLE-HOLDER 105030-4210
14. NOZZLE 105015-8540
15. NOZZLE SET

Include in #1:

106671-5081 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 691 9400619691
ZEXEL 106671-5081 1066715081


Zexel num
Bosch num
Firm num
Name
106671-5081 
106671-5082 
9 400 619 691 
   
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   105780-8140
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
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-4-2-6- 3-5
Pre-stroke mm   3.9 3.85 3.95
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   10.3
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   163.2 161.2 165.2
Max. variation between cylinders %   0 -4 4
Basic   *
Fixing the lever   *
Boost pressure kPa   36 36
Boost pressure mmHg   270 270
Injection quantity adjustment_02
Adjusting point   -
Rack position   5.7+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   16 15 17
Max. variation between cylinders %   0 -10 10
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.
 
Injection quantity adjustment_03
Adjusting point   D
Rack position   9.05
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   129.1 125.1 133.1
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   300 300 300
Rack position   9.05
Boost pressure kPa   3.3 3.3 5.3
Boost pressure mmHg   25 25 40
Boost compensator adjustment_02
Pump speed r/min   300 300 300
Rack position   10.65
Boost pressure kPa   22.7 16 29.4
Boost pressure mmHg   170 120 220
Timer adjustment
Pump speed r/min   1000--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   950
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1050
Advance angle deg.   1.5 1 2
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106671-5081
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)Variable speed specification. (5)Boost compensator stroke (6)Rack limit using stop lever (7)Set idle sub-spring (with the lever free). (8)Damper spring setting (9)Perform governor adjustment at an ambient temperature of at least 15 deg C (boost compensator start spring is shape memory alloy).
----------
RT=1 TH=2.4mm
----------

Speed control lever angle

Test data 106671-5081
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=21deg+-5deg b=16deg+-5deg

0000000901

Test data 106671-5081
F:Full load (1)Fix the lever.
----------

----------
a=24deg+-5deg

Stop lever angle

Test data 106671-5081
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Use the hole at R = bb
----------
aa=10.65mm bb=25mm
----------
a=11deg+-5deg b=30.5deg+-5deg

0000001501 RACK SENSOR

Test data 106671-5081
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=600r/min Ra=10.3mm
----------

Timing setting

Test data 106671-5081
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)Secondary timing stamping position for the No. 1 cylinder's beginning of injection (5)Pump vertical direction (6)Direction of rotation (7)Pointer (8)Timing device stamping (9)Pointer stamping (10)Timing device (11)Move b deg and stamp both at the same time as shown above. (12)Outside circumference of timing device
----------

----------
a=(30deg) b=1deg30min




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