Information injection-pump assembly
BOSCH
9 400 619 773
9400619773
ZEXEL
106673-2993
1066732993
Rating:
Service parts 106673-2993 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME151161
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Include in #1:
106673-2993
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 773
9400619773
ZEXEL
106673-2993
1066732993
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0220
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
1-5-3-6-
2-4
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 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
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.9
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
147
143.3
150.7
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8+-0.5
Pump speed
r/min
385
385
385
Each cylinder's injection qty
mm3/st.
21
17.8
24.2
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.9)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
147
146
148
Basic
*
Fixing the lever
*
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.05
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
143.5
139.5
147.5
Fixing the lever
*
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.75
)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
142
136
148
Fixing the lever
*
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
(R2-1.3)
Boost pressure
kPa
4
2.7
5.3
Boost pressure
mmHg
30
20
40
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1(12
.9)-1)
Boost pressure
kPa
10.7
10.7
10.7
Boost pressure
mmHg
80
80
80
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)Boost compensator stroke: BCL
(4)Damper spring setting
----------
T1=AC25 BCL=(1.3)+-0.1mm
----------
----------
T1=AC25 BCL=(1.3)+-0.1mm
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
(3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=1deg+-5deg b=(39deg)+-3deg
----------
aa=37.5mm
----------
a=1deg+-5deg b=(39deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Normal engine position (Rack position corresponding to bb)
(3)Set the stopper bolt so that speed = cc and rack position = dd and confirm non-injection.
----------
aa=54mm bb=18mm cc=1100r/min dd=3.5+-0.3mm
----------
a=(20.5deg) b=29.5deg+-5deg c=40deg+-5deg
----------
aa=54mm bb=18mm cc=1100r/min dd=3.5+-0.3mm
----------
a=(20.5deg) b=29.5deg+-5deg c=40deg+-5deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325r/min Ra=7.6+-0.1mm
----------
----------
N1=325r/min Ra=7.6+-0.1mm
----------
0000001601 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1100r/min Ra=R1(12.9)+1.05mm
----------
----------
N1=1100r/min Ra=R1(12.9)+1.05mm
----------
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=5deg
----------
a=(2deg)
----------
aa=5deg
----------
a=(2deg)
Information:
(1) 7S7144 Spring for valves (new): Length under test force ... 44.86 mm (1.766 in)Test force ... 257 25 N (57.7 4.5 lb)Use again minimum load at length under test force ... 217 N (48.83 lb)Length of spring at valve open position ... 32.28 mm (1.271 in)Use again minimum load at valve open position ... 658 N (148.5 lb)Free length after test ... 52.07 mm (2.05 in)Outside diameter ... 35.21 mm (1.386 in)Spring must not be bent more than ... 1.82 mm (.072 in)(2) Height to top of valve guide ... 22.23 0.25 mm (.875 .010 in)(3) Diameter of valve stem (new) ... 9.441 0.008 mm (.3717 .0003 in) Use again minimum diameter ... 9.408 mm (.3704 in)Bore in valve guide with guide installed in the head.Minimum permissible (new) ... 9.456 mm (.3723 in)Maximum permissible (worn) ... 9.581 mm (.3772 in)(4) Valve lip thickness: 6N9916 Exhaust Valve Use again minimum ... 2.69 mm (.106 in)7N753 Exhaust Valve Use again minimum ... 2.44 mm (.096 in)7N572 Intake Valve Use again minimum ... 2.69 mm (.106 in)6N9915 Intake Valve Use again minimum ... 2.44 mm (.096 in)(5) Diameter of valve head: Exhaust valve ... 48.16 0.13 mm (1.896 .005 in)Intake valve ... 51.31 0.13 mm (2.020 .005 in)(6) Angle of valve face ... 29 1/4 1/4° (7) Depth of bore in head for valve seat insert ... 12.28 0.13 mm (.483 .005 in)(8) Diameter of valve seat insert for exhaust valve ... 50.889 0.013 mm (2.0035 .0005 in) Bore in head for valve seat insert for exhaust valve ... 50.813 0.030 mm (2.0005 .0012 in)Diameter of valve seat insert for intake valve ... 52.032 0.013 mm (2.0485 .0005 in)Bore in head for valve seat insert for intake valve ... 51.956 0.030 mm (2.0455 .0012 in)(9) Angle of face of valve seat insert ... 30 1°(10) Maximum permissible width of valve seat (intake and exhaust) ... 1.93 mm (.076 in) Minimum permissible width of valve seat (intake and exhaust) ... 1.14 mm (.045 in)(11) Dimension from top of closed valve to face of head: Minimum permissible dimension for 6N9916 or 7N753 Exhaust Valve ... 0.66 mm (.026 in)Minimum permissible dimension for 6N9915, 2W2620, or 7N752 Intake Valve ... 0.15 mm (.006 in)(12) Outside diameter of the face of the valve seat insert: Exhaust seat ... 46.02 mm (1.812 in)Maximum permissible, exhaust seat ... 47.29 mm (1.862 in)Intake seat ... 49.28 mm (1.940 in)Maximum permissible, intake seat ... 50.55 mm (1.990 in)(13) Angle to grind seat face of the insert to get a reduction of maximum seat diameter ... 15°Procedure to Check Intake Valve Timing
1. Check the No. 1 intake valve clearance with the engine stopped. The valve clearance must be 0.30 to 0.46 mm (.012 to .018 in). If the valve clearance is not in this range, adjust the clearance to .038 mm (.015 in).2. Mark Top Center Position
1. Check the No. 1 intake valve clearance with the engine stopped. The valve clearance must be 0.30 to 0.46 mm (.012 to .018 in). If the valve clearance is not in this range, adjust the clearance to .038 mm (.015 in).2. Mark Top Center Position