106673-7391 ZEXEL 9 400 619 457 BOSCH INJECTION-PUMP ASSEMBLY 9400619457 1066737391

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 457 9400619457

ZEXEL 106673-7391 1066737391

Service parts 106673-7391 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-1030

3. GOVERNOR 105407-6141

4. SUPPLY PUMP 105207-1200

5. AUTOM. ADVANCE MECHANIS 105636-1700

6. COUPLING PLATE 105663-0550

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7111

11. Nozzle and Holder ME056473

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105041-4420

14. NOZZLE

105015-6150

15. NOZZLE SET

Include in #1:

106673-7391 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 457 9400619457

ZEXEL 106673-7391 1066737391

Zexel num

Bosch num

Firm num

Name

106673-7391
106673-7392

9 400 619 457

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 131424-4620

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 1-5-3-6- 2-4

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor 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 10.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 160 157 163

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Injection quantity adjustment_02

Adjusting point B

Rack position 6+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 8 5.4 10.6

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 750 750 750

Rack position R1-1.3

Boost pressure kPa 4 1.3 6.7

Boost pressure mmHg 30 10 50

Boost compensator adjustment_02

Pump speed r/min 750 750 750

Rack position R1(10.5)

Boost pressure kPa 40 33.3 46.7

Boost pressure mmHg 300 250 350

Timer adjustment

Pump speed r/min 1200++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1200.

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 2 2 2

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)At excess fuel lever operation (at boost pressure 0): L1 (4)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke (7)Rack difference between N = N1 and N = N2
----------
K=9 L1=11.25+-0.1mm N1=900r/min N2=400r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Set the pump speed at aa (3)Set the pump speed at bb.
----------
aa=750r/min bb=900r/min
----------
a=4deg+-5deg b=21deg+-5deg c=6deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=48.5deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa (point D) at boost pressure 0.
----------
aa=11.25+-0.1mm
----------
a=(18deg) b=(12deg)

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=(7deg)