106676-2070 ZEXEL 9 400 611 903 BOSCH INJECTION-PUMP ASSEMBLY 9400611903 1066762070

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 903 9400611903

ZEXEL 106676-2070 1066762070

Service parts 106676-2070 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-1320

3. GOVERNOR 105407-7070

4. SUPPLY PUMP 105207-1200

5. AUTOM. ADVANCE MECHANIS 105681-2170

6. COUPLING PLATE 105663-0550

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7550

11. Nozzle and Holder ME158263

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

13. NOZZLE-HOLDER 105041-4130

14. NOZZLE

15. NOZZLE SET 105019-0700

Include in #1:

106676-2070 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 903 9400611903

ZEXEL 106676-2070 1066762070

Zexel num

Bosch num

Firm num

Name

106676-2070
106676-2071

9 400 611 903

INJECTION-PUMP ASSEMBLY
6D24T * 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 8.9

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 123 120 126

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_02

Adjusting point B

Rack position 4.4+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 9.5 6.9 12.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 145 125 165

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-1.25

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(8.9)

Boost pressure kPa 17.3 10.6 24

Boost pressure mmHg 130 80 180

Timer adjustment

Pump speed r/min 0

Advance angle deg. 2.5 2 3

Timer adjustment_02

Pump speed r/min 300

Advance angle deg. 2.5 2 3

Remarks
Start

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 0 0 0

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)RACK LIMIT (4)The torque control spring must does not have a set force. (5)Boost compensator stroke: BCL (6)Set idle sub-spring (7)Main spring setting
----------
K=6 BCL=1.25+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(1deg)+-5deg b=(21deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the outer screw where it contacts the inside (seal at delivery) (2)Pump speed aa and rack position bb (to be sealed at delivery) (3)Stopper bolt setting (4)No return spring
----------
aa=0r/min bb=1-0.5mm
----------
a=55deg+-5deg b=70deg+-5deg

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=12deg
----------
a=(6deg)