106691-4112 ZEXEL 9 400 613 307 BOSCH INJECTION-PUMP ASSEMBLY 9400613307 1066914112

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 307 9400613307

ZEXEL 106691-4112 1066914112

Service parts 106691-4112 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106069-7572

3. GOVERNOR 105407-8202

4. SUPPLY PUMP

105217-6030

5. AUTOM. ADVANCE MECHANIS 105681-6110

6. COUPLING PLATE 105663-0920

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-5090

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105041-7130

14. NOZZLE 105025-4060

15. NOZZLE SET

Include in #1:

106691-4112 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 307 9400613307

ZEXEL 106691-4112 1066914112

Zexel num

Bosch num

Firm num

Name

106691-4112
106691-4113

9 400 613 307

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 105780-8140

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 134424-4120

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.75 3.7 3.8

Rack position
Point A or more. R=A++

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 11.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 137.5 135.5 139.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Injection quantity adjustment_02

Adjusting point -

Rack position 7.5+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 21 19.5 22.5

Max. variation between cylinders % 0 -15 15

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.

Injection quantity adjustment_03

Adjusting point E

Rack position 11.9++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 160 150 170

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 10.1

Boost pressure kPa 8 6.7 9.3

Boost pressure mmHg 60 50 70

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 11.15

Boost pressure kPa 24 24 24

Boost pressure mmHg 180 180 180

Timer adjustment

Pump speed r/min (N1+50)- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min N1

Advance angle deg. 0.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 2 1.7 2.3

Remarks
Measure the actual speed, stop

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 (4)Boost compensator stroke (5)Set idle sub-spring (6)Main spring setting (7)Rack difference between N = N1 and N = N2
----------
K=16 N1=1000r/min N2=500r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=69mm
----------
a=(9deg)+-5deg b=(28deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb. (2)Normal
----------
aa=1-0.5mm bb=0r/min
----------
a=33deg+-5deg b=70deg+-5deg

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=8deg
----------
a=(140deg)