Information injection-pump assembly
BOSCH
9 400 619 692
9400619692
ZEXEL
106671-5260
1066715260
Rating:
Service parts 106671-5260 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1660096575
12.
Open Pre:MPa(Kqf/cm2)
22.6{230}
15.
NOZZLE SET
Include in #1:
106671-5260
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 692
9400619692
ZEXEL
106671-5260
1066715260
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-0020
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
171
169
173
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Boost pressure
kPa
78.6
78.6
Boost pressure
mmHg
590
590
Injection quantity adjustment_02
Adjusting point
C
Rack position
10.25+-0
.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
136.5
133.5
139.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
7.1+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
21
20
22
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
400
400
400
Rack position
(10.25)
Boost pressure
kPa
33.3
26.6
40
Boost pressure
mmHg
250
200
300
Boost compensator adjustment_02
Pump speed
r/min
400
400
400
Rack position
11.3
Boost pressure
kPa
69.3
66.6
72
Boost pressure
mmHg
520
500
540
Timer adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
1
0.5
1.5
Remarks
Finish
Finish
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)Set idle sub-spring
(5)Main spring setting
----------
K=10 L1=13.6+-0.1mm
----------
----------
K=10 L1=13.6+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=2deg+-5deg b=21deg+-5deg
----------
----------
a=2deg+-5deg b=21deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26deg+-5deg b=53deg+-5deg
----------
----------
a=26deg+-5deg b=53deg+-5deg
0000001101
N:Normal
B:When boosted
(1)Rack position = aa (at boost pressure = bb)
----------
aa=13.6+-0.1mm bb=0kPa(0mmHg)
----------
a=(18deg) b=(18deg)
----------
aa=13.6+-0.1mm bb=0kPa(0mmHg)
----------
a=(18deg) b=(18deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(20deg)
----------
----------
a=(20deg)
Information:
Start By:a. remove timing gear cover
Do not disconnect the air line from the air compressor governor until the air pressure is zero.
1. Loosen the bleed valves, and release the air pressure in the air tank. 2. Disconnect the lines from air compressor (1), and remove the air compressor. 3. Remove sleeve (2) from air compressor drive gear (3). 4. Remove the nut and washer that holds the air compressor drive gear to the air compressor. Use tooling (A) to remove air compressor drive gear (3) from the air compressor. 5. Remove nuts (4) and plate (5). Remove gear assembly (6) from the shaft. 6. If damaged, remove bearing (7) from gear assembly (6) with tooling (B) and a press. 7. Remove three nuts (8) and the washers from the adapter assembly studs.
Typical Example8. Remove adapter assembly (9) from the timing gear plate. 9. Remove shaft (10), O-ring seal (11) and sleeve (12) from the adapter assembly.Install Air Compressor And Accessory Drive
1. Install sleeve (12) into the adapter assembly.2. Install shaft (10) and O-ring seal (11) on the adapter assembly. 3. Put adapter assembly (9) in position on the timing gear plate. Fasten it with the three nuts and washers. 4. Install the bearing in gear assembly (6) with tooling (A) and a press. Install the bearing until it is 1.5 0.5 mm (.06 .02 in.) below the surface of the gear as shown. 5. Put gear assembly (6) in position on the shaft.6. Put plate (5) in position, and install three nuts (4) to hold it. 7. Put air compressor drive gear (3) in position on the air compressor shaft, and install the washer and nut (13). Tighten the nut to a torque of 200 25 N m (150 18 lb.in.). Tap the gear with a hammer and tighten nut (13) again to a torque of 200 25 N m (150 18 lb.ft.). 8. Install sleeve (2) on gear (3). 9. Put a gasket in position on air compressor (1) and install the air compressor on the timing cover plate.End By:a. install timing gear cover
Do not disconnect the air line from the air compressor governor until the air pressure is zero.
1. Loosen the bleed valves, and release the air pressure in the air tank. 2. Disconnect the lines from air compressor (1), and remove the air compressor. 3. Remove sleeve (2) from air compressor drive gear (3). 4. Remove the nut and washer that holds the air compressor drive gear to the air compressor. Use tooling (A) to remove air compressor drive gear (3) from the air compressor. 5. Remove nuts (4) and plate (5). Remove gear assembly (6) from the shaft. 6. If damaged, remove bearing (7) from gear assembly (6) with tooling (B) and a press. 7. Remove three nuts (8) and the washers from the adapter assembly studs.
Typical Example8. Remove adapter assembly (9) from the timing gear plate. 9. Remove shaft (10), O-ring seal (11) and sleeve (12) from the adapter assembly.Install Air Compressor And Accessory Drive
1. Install sleeve (12) into the adapter assembly.2. Install shaft (10) and O-ring seal (11) on the adapter assembly. 3. Put adapter assembly (9) in position on the timing gear plate. Fasten it with the three nuts and washers. 4. Install the bearing in gear assembly (6) with tooling (A) and a press. Install the bearing until it is 1.5 0.5 mm (.06 .02 in.) below the surface of the gear as shown. 5. Put gear assembly (6) in position on the shaft.6. Put plate (5) in position, and install three nuts (4) to hold it. 7. Put air compressor drive gear (3) in position on the air compressor shaft, and install the washer and nut (13). Tighten the nut to a torque of 200 25 N m (150 18 lb.in.). Tap the gear with a hammer and tighten nut (13) again to a torque of 200 25 N m (150 18 lb.ft.). 8. Install sleeve (2) on gear (3). 9. Put a gasket in position on air compressor (1) and install the air compressor on the timing cover plate.End By:a. install timing gear cover