Information injection-pump assembly
BOSCH
9 400 611 796
9400611796
ZEXEL
106681-4281
1066814281
Rating:
Service parts 106681-4281 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
35A61-00010
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106681-4281
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 796
9400611796
ZEXEL
106681-4281
1066814281
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
105780-8130
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 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Overflow valve
131424-3420
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
2.8
2.75
2.85
Rack position
Point A R=A
Point A R=A
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
A
Rack position
11.8
Pump speed
r/min
975
975
975
Average injection quantity
mm3/st.
334
325
343
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
160
160
Boost pressure
mmHg
1200
1200
Remarks
Injection at all cylinders.
Injection at all cylinders.
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.6+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
20.5
17.5
23.5
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Injection only at cylinders 1, 3, 4 and 6.
Injection only at cylinders 1, 3, 4 and 6.
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-3.2
Boost pressure
kPa
62.7
60
65.4
Boost pressure
mmHg
470
450
490
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(11.8)
Boost pressure
kPa
147
140.3
153.7
Boost pressure
mmHg
1100
1050
1150
Timer adjustment
Pump speed
r/min
-
Advance angle
deg.
0
0
0
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
4
3.5
4.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)The torque control spring does not operate.
(3)Boost compensator stroke: BCL
(4)Idle sub spring setting: L1.
----------
K=25 BCL=3.2+-0.1mm L1=7.5-0.5mm
----------
----------
K=25 BCL=3.2+-0.1mm L1=7.5-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)At the center of the lever key groove
----------
----------
a=(3deg)+-5deg b=(31deg)+-5deg
----------
----------
a=(3deg)+-5deg b=(31deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa, rack position bb
----------
aa=0r/min bb=1-0.5mm
----------
a=33deg+-5deg b=(73deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=33deg+-5deg b=(73deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(110deg)
----------
----------
a=(110deg)
Information:
1. Remove shaft (2). Remove pin (1) from the shaft.2. Remove pins (3) from the flyweights. Remove flyweights (4). 3. Remove ring, races (6) and the bearing from riser (follower) (5). 4. Remove cover (7) and spring (8) from the governor housing. There is force on the cover from the spring.5. Remove seal (9) from the cover. 6. Remove cover (10) for the low and high idle adjustments.7. Remove locknut and screw (13) for the high idle adjustment.8. Remove bolt (15) and the washers for the low idle adjustment.9. Remove spring (16) and the guide.10. Remove pin (14) and plate (11).11. Remove shaft (12) from the housing. 12. Remove two spacers (17) and pin (18) from the shaft. 13. Remove shaft (19) from the governor housing.14. Remove washer (20) and levers (21) and (22) from the governor housing. 15. Remove seal (23) and the bearing.16. Remove seals (24) and (25) from the governor housing.Assemble Governor
1. Install the bearing and seal in the housing with tool (A). The lip of the seal must be toward the bearing. 2. Install seal (1) in housing with tool (A). The lip of the seal must be toward inside of housing.3. Install seal (2) in the housing with tool (B). The lip of the seal must be toward the inside of the housing. 4. Install shaft (3) in the housing. 5. Install plates (4), spacers (8) and pin (7) on shaft (5).6. Install shaft (5) in the housing and through washer (9) and levers (6). 7. Install pin (11) in the holes of the plates.8. Install screw (10) and the locknut for the high idle adjustment.9. Install spring (13) and the guide.10. Install bolt (12) and the washer for the low idle adjustment.11. Push plate and pin (11) over toward bolt (12) and tighten the bolt. 12. Install the seal in cover (14) with tooling (B). The lip of the seal must be toward the inside. 13. Install spring (15) in the cover. Install cover (14) on the housing.
Spring (15) must be installed with the end of the spring in the position shown.
14. Install the cover (16) for the idle adjustment screws. 15. Install bearing (19) between races (18) on riser (follower) (17). Install ring (20). Ring (20) holds the washers on the riser (follower).16. Install the pin in shaft (23). 17. Install flyweights (22) and pin (21).18. Install shaft (23) in the flyweight assembly.end by: a) connection of governor to fuel injection pump housingb) Make adjustment of fuel system setting (See Fuel System Setting in Testing and Adjusting.)
1. Install the bearing and seal in the housing with tool (A). The lip of the seal must be toward the bearing. 2. Install seal (1) in housing with tool (A). The lip of the seal must be toward inside of housing.3. Install seal (2) in the housing with tool (B). The lip of the seal must be toward the inside of the housing. 4. Install shaft (3) in the housing. 5. Install plates (4), spacers (8) and pin (7) on shaft (5).6. Install shaft (5) in the housing and through washer (9) and levers (6). 7. Install pin (11) in the holes of the plates.8. Install screw (10) and the locknut for the high idle adjustment.9. Install spring (13) and the guide.10. Install bolt (12) and the washer for the low idle adjustment.11. Push plate and pin (11) over toward bolt (12) and tighten the bolt. 12. Install the seal in cover (14) with tooling (B). The lip of the seal must be toward the inside. 13. Install spring (15) in the cover. Install cover (14) on the housing.
Spring (15) must be installed with the end of the spring in the position shown.
14. Install the cover (16) for the idle adjustment screws. 15. Install bearing (19) between races (18) on riser (follower) (17). Install ring (20). Ring (20) holds the washers on the riser (follower).16. Install the pin in shaft (23). 17. Install flyweights (22) and pin (21).18. Install shaft (23) in the flyweight assembly.end by: a) connection of governor to fuel injection pump housingb) Make adjustment of fuel system setting (See Fuel System Setting in Testing and Adjusting.)