106682-3050 ZEXEL 9 400 619 776 BOSCH INJECTION-PUMP ASSEMBLY 9400619776 1066823050

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 776 9400619776

ZEXEL 106682-3050 1066823050

Service parts 106682-3050 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-2941

3. GOVERNOR 105407-6390

4. SUPPLY PUMP 105237-5110

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0970

7. COUPLING PLATE 156639-3420

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-8321

11. Nozzle and Holder 236003150B

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

13. NOZZLE-HOLDER 105030-3531

14. NOZZLE

15. NOZZLE SET 105019-2050

Include in #1:

106682-3050 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 776 9400619776

ZEXEL 106682-3050 1066823050

Zexel num

Bosch num

Firm num

Name

106682-3050
106682-3051

9 400 619 776

INJECTION-PUMP ASSEMBLY
* K 14CA PE6P,6PD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000

Overflow valve 134424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 3.3 3.27 3.33

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 14

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 409 405 413

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 98.6 98.6

Boost pressure mmHg 740 740

Injection quantity adjustment_02

Adjusting point B

Rack position R2(10.8)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 192.5 189.5 195.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position 6.2+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 10 7 13

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 700 700 700

Rack position R2(10.8)

Boost pressure kPa 26.7 24 29.4

Boost pressure mmHg 200 180 220

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(14)

Boost pressure kPa 85.3 85.3 85.3

Boost pressure mmHg 640 640 640

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)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure) (4)Damper spring setting (5)Boost compensator stroke: BCL
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K=13 L1=16.5+-0.1mm BCL=(3.2)mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(12deg)+-5deg b=(32deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Contacts inner stopper. (2)Contacts outer stopper.
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a=27deg+-5deg b=53deg+-5deg c=(11deg)

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0. (2)Drive side
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aa=16.5+-0.1mm
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a=(18deg) b=(15deg)

0000001501 Q ADJUSTMENT PIPING

Fuel hose adjusting procedure Fuel inlet hose A Fuel inlet hose B Fuel hose C ( (for bypass) (D) Overflow valve 1. Because the pump gallery is divided into two, be careful of the fuel piping. (1)Connect the fuel inlet hose to port (a). (2)Connect the fuel hose (for bypass) to ports (b) and (c). (3)Assemble the overflow valve (D) to the fuel outlet hose and connect to port (d).
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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)-
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aa=20deg
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a=(50deg)