103662-3370 ZEXEL 9 400 611 835 BOSCH INJECTION-PUMP ASSEMBLY 9400611835 1036623370

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 835 9400611835

ZEXEL 103662-3370 1036623370

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Buy INJECTION-PUMP ASSEMBLY 103662-3370 zexel genuine, new aftermarket engine parts with delivery

Service parts 103662-3370 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 103066-8460

3. GOVERNOR 105455-1160

4. SUPPLY PUMP 105235-1781

5. AUTOM. ADVANCE MECHANIS 105649-0070

6. COUPLING PLATE 105664-0490

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4812

11. Nozzle and Holder 6162-13-8902

12. Open Pre:MPa(Kqf/cm2) 29.4{300}

13. NOZZLE-HOLDER 105041-7102

14. NOZZLE 105025-3010

15. NOZZLE SET

Include in #1:

101608-1710 as _

101608-1711

103662-3370 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 835 9400611835

ZEXEL 103662-3370 1036623370

Zexel num

Bosch num

Firm num

Name

103662-3370
103662-3371

9 400 611 835

INJECTION-PUMP ASSEMBLY
SA6D170A * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

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 8-4-1500

Overflow valve 131425-2020

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)
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 18.8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 512 507 517

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 84.6 84.6

Boost pressure mmHg 635 635

Injection quantity adjustment_02

Adjusting point B

Rack position 10.3+-0. 5

Pump speed r/min 315 315 315

Average injection quantity mm3/st. 46.5 41.5 51.5

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 370 370 390

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-1.3

Boost pressure kPa 50 47.3 52.7

Boost pressure mmHg 375 355 395

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(18.8)

Boost pressure kPa 71.3 64.6 78

Boost pressure mmHg 535 485 585

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)Stop lever at stopping (with the speed lever at full) (5)Set idle sub-spring (6)Main spring setting (7)Boost compensator stroke: BCL
----------
K=19 BCL=1.3+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
----------
aa=98mm
----------
a=(13deg)+-5deg b=30deg+-3deg c=(33deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)The clearance from the set screw must be aa. (2)Use the hole at R = bb (3)Set the screw at speed = cc and rack position = dd (at speed lever Full). (4)No return spring
----------
aa=2+1mm bb=40mm cc=100r/min dd=5-0.2mm
----------
a=16deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

Information:

1. Remove plug (1) from the fuel injection pump housing.2. Use Tool (D) to loosen nut (2) for the fuel injection pump to be removed. Disconnect the fuel injection line nuts, and remove the felt washer. 3. Install Tool (A) in the fuel pump housing as shown with the square end down. Use a small amount of hand force to push down on Tool (A) while the control lever is moved forward to the "FUEL ON" position. Rack travel will stop in the center (zero) position. Hold a light forward force on the governor control lever to keep the fuel racks in the center (zero) position.4. Use Tool (B) to remove bushing (3) from the fuel injection pump housing. 5. Remove bushing (3) and O-ring seal (4).
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed in their original location.
6. Use Tool (C) to remove fuel injection pump (5). 7. Remove spacer (6) from the fuel injection pump housing. Make a note of the position from which each spacer was removed so each spacer can be installed in its original position.
Be careful when the fuel injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. The check assemblies are made as a set. Do not mix the parts of the different check assemblies. Do not remove or make any adjustments of the gear segment on the plunger. It has been preset at the factory. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
8. Disassemble the fuel injection pump as follows: Remove ring (7). Separate bonnet (10) from barrel (9). Remove the spring and the check assembly from the bonnet. Remove plunger (8), the washer and spring from barrel (9).Install Fuel Injection Pumps
1. Inspect all parts for wear or damage. The plunger and barrel are serviced only as an assembly. 2. Put clean diesel fuel on plunger (1). Put plunger (1), washer (6) and spring (2) in position on barrel (3).3. Put check valve assembly (7) and spring (8) in bonnet (9). Connect bonnet (9) and barrel (3) together with ring (4). 4. Put spacer (10) into position in the pump housing bore. Be sure the correct spacer is with each pump. 5. Note the location of dowels (11) and (12) in the fuel injection pump housing. These dowels are for alignment of the fuel injection pump. 6. Slot (13) in gear segment (5) must align with dowel (11).7. Groove (14) must engage with dowel (12). 8. Use Tool (A) to put the fuel racks in the center (zero) position. See Remove Fuel Injection Pumps.9. Use Tool