Rating:
Information injection-pump assembly
BOSCH
9 400 619 691
9400619691
ZEXEL
106671-5081
1066715081
Service parts 106671-5081 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1660096573
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/22.6{230}.
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
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 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
1-4-2-6-
3-5
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 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
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
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.
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
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
Finish
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)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
----------
----------
RT=1 TH=2.4mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=21deg+-5deg b=16deg+-5deg
----------
----------
a=21deg+-5deg b=16deg+-5deg
0000000901
F:Full load
(1)Fix the lever.
----------
----------
a=24deg+-5deg
----------
----------
a=24deg+-5deg
Stop lever angle
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
----------
aa=10.65mm bb=25mm
----------
a=11deg+-5deg b=30.5deg+-5deg
0000001501 RACK SENSOR
(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
----------
----------
N1=600r/min Ra=10.3mm
----------
Timing setting
(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
----------
----------
a=(30deg) b=1deg30min