106671-9991 ZEXEL 9 400 612 225 BOSCH INJECTION-PUMP ASSEMBLY 9400612225 1066719991

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 225 9400612225

ZEXEL 106671-9991 1066719991

Service parts 106671-9991 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-6290

3. GOVERNOR 105407-7771

4. SUPPLY PUMP

105217-6030

5. AUTOM. ADVANCE MECHANIS 105681-6010

6. COUPLING PLATE 105663-0920

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-5060

11. Nozzle and Holder 6152-12-3800

12. Open Pre:MPa(Kqf/cm2) 27.5{280}

13. NOZZLE-HOLDER 105041-7130

14. NOZZLE 105025-3530

15. NOZZLE SET

Include in #1:

106671-9991 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 225 9400612225

ZEXEL 106671-9991 1066719991

Zexel num

Bosch num

Firm num

Name

106671-9991
106671-9992

9 400 612 225

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 131424-1520

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 3.8 3.75 3.85

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

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

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9.3

Pump speed r/min 1025 1025 1025

Average injection quantity mm3/st. 187.5 185.5 189.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 48 48

Boost pressure mmHg 360 360

Injection quantity adjustment_02

Adjusting point C

Rack position 5.6+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 14 12.5 15.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1-1.65

Boost pressure kPa 13.3 10.6 16

Boost pressure mmHg 100 80 120

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(9.3)

Boost pressure kPa 34.7 34.7 34.7

Boost pressure mmHg 260 260 260

Timer adjustment

Pump speed r/min 800--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 950

Advance angle deg. 2.25 1.95 2.55

Remarks
Finish

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: RAL (4)Boost compensator stroke (5)Rack difference between N = N1 and N = N2
----------
K=10 RAL=9.8+-0.1mm N1=1025r/min N2=220r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
----------
aa=85mm
----------
a=1deg+-5deg b=22deg+-5deg c=35deg+-3deg

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)
----------

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=9deg
----------
a=(150deg)