106671-9491 ZEXEL 9 400 611 167 BOSCH INJECTION-PUMP ASSEMBLY 9400611167 1066719491

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 167 9400611167

ZEXEL 106671-9491 1066719491

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Cross reference number

BOSCH 9 400 611 167 9400611167

ZEXEL 106671-9491 1066719491

Zexel num

Bosch num

Firm num

Name

106671-9491

9 400 611 167

DAEWOO

INJECTION-PUMP ASSEMBLY
DE12 * 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 131424-4420

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4.7 4.65 4.75

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 -

Rack position 13.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 121.5 118.5 124.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 8.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 11 9.5 12.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.2)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 121.5 119.5 123.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.3

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 121.5 115.5 127.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 110 104 116

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 85 105

Fixing the lever *

Rack limit *

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. 5.5 5 6

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Microswitch adjustment unnecessary. (4)RACK LIMIT (5)Damper spring setting
----------
T1=AE19
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=70mm
----------
a=14deg+-5deg b=(35deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Rack position bb (3)Set the stopper screw. (After setting, apply red paint.)
----------
aa=40mm bb=1.5+-0.3mm
----------
a=20deg+-5deg b=44deg+-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=10deg
----------
a=(70deg)

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
There have been instances of the following diagnostic codes becoming active:
Table 1
J1939 Code CDL Code Code Description
1184-3 3782-3 Engine Turbocharger #1 Turbine Outlet Temperature : Voltage Above Normal
1184-4 3782-4 Engine Turbocharger #1 Turbine Outlet Temperature : Voltage Below Normal
3242-3 2452-3 DPF #1 Intake Temperature Sensor : Voltage Above Normal
3242-4 2452-4 DPF #1 Intake Temperature Sensor : Voltage Below Normal
4360-3 3105-3 Aftertreatment #1 SCR Catalyst Intake Gas Temperature Sensor : Voltage Above Normal
4360-4 3105-4 Aftertreatment #1 SCR Catalyst Intake Gas Temperature Sensor : Voltage Below Normal One root cause of the diagnostic codes has been identified as electrical noise overwriting data on the memory chip of the DPF/SCR intake temperature sensor. Improved sensor firmware has resolved this issue.A fault could not be found with some of the returned parts. A new troubleshooting procedure has been released. Refer to Troubleshooting, Sensor Signal (PWM) - Test.