Information injection-pump assembly
BOSCH
9 400 619 776
9400619776
ZEXEL
106682-3050
1066823050
Rating:
Service parts 106682-3050 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
8.
_
9.
_
11.
Nozzle and Holder
236003150B
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
14.
NOZZLE
Include in #1:
106682-3050
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 776
9400619776
ZEXEL
106682-3050
1066823050
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
134424-0820
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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
3.3
3.27
3.33
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
14
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
409
405
413
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
98.6
98.6
Boost pressure
mmHg
740
740
Injection quantity adjustment_02
Adjusting point
B
Rack position
R2(10.8)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
192.5
189.5
195.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
6.2+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
10
7
13
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R2(10.8)
Boost pressure
kPa
26.7
24
29.4
Boost pressure
mmHg
200
180
220
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
R1(14)
Boost pressure
kPa
85.3
85.3
85.3
Boost pressure
mmHg
640
640
640
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)Damper spring setting
(5)Boost compensator stroke: BCL
----------
K=13 L1=16.5+-0.1mm BCL=(3.2)mm
----------
----------
K=13 L1=16.5+-0.1mm BCL=(3.2)mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(12deg)+-5deg b=(32deg)+-5deg
----------
----------
a=(12deg)+-5deg b=(32deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Contacts inner stopper.
(2)Contacts outer stopper.
----------
----------
a=27deg+-5deg b=53deg+-5deg c=(11deg)
----------
----------
a=27deg+-5deg b=53deg+-5deg c=(11deg)
0000001101
N:Normal
B:When boosted
(1)Rack position = aa at boost pressure 0.
(2)Drive side
----------
aa=16.5+-0.1mm
----------
a=(18deg) b=(15deg)
----------
aa=16.5+-0.1mm
----------
a=(18deg) b=(15deg)
0000001501 Q ADJUSTMENT PIPING
Fuel hose adjusting procedure
Fuel inlet hose A
Fuel inlet hose B
Fuel hose C ( (for bypass)
(D) Overflow valve
1. Because the pump gallery is divided into two, be careful of the fuel piping.
(1)Connect the fuel inlet hose to port (a).
(2)Connect the fuel hose (for bypass) to ports (b) and (c).
(3)Assemble the overflow valve (D) to the fuel outlet hose and connect to port (d).
----------
----------
----------
----------
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=20deg
----------
a=(50deg)
----------
aa=20deg
----------
a=(50deg)
Information:
1. Remove oil supply tube (3), suction bell (2) and suction bell tube (1). 2. Remove bolts (4) that hold the oil pump to the cylinder block and remove oil pump (5).Install Oil Pump
1. Put oil pump (3) in position on the engine. Install the bolts that hold the oil pump to the cylinder block.2. Put clean oil on the O-ring seals of the tubes.3. Install suction bell tube (2), suction bell and oil supply tube (1).end by:a) install oil panDisassemble Oil Pump
start by:a) remove oil pump1. Remove the bolt and washer that hold the gear on the shaft. 2. Use tooling (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve.4. Remove the spring and bypass valve.5. Remove cover (2) from the pump body. 6. Use tooling (B) and remove the bearings from the cover. 7. Remove gears (5) from pump body (4).8. Use tooling (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use tooling (A) to install the bearings in the pump body. Install the bearings so the split in the bearings is 30° 15° from the center line of the oil pump outlet passage (2). 2. Install idler gear (1) and drive gear (3) in the oil pump body. Put clean engine oil on the bearings and the gears. 3. Use tooling (A) and install the bearings in cover (4). Install the bearings so the split in the bearings is 30° 15° from the center line of the bearing bores toward oil pump outlet passage (2).4. Install bypass valve (5), spring (6) and the retainer.5. Install the key on the shaft. 6. Install gear (7) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.end by:a) install oil pump
1. Put oil pump (3) in position on the engine. Install the bolts that hold the oil pump to the cylinder block.2. Put clean oil on the O-ring seals of the tubes.3. Install suction bell tube (2), suction bell and oil supply tube (1).end by:a) install oil panDisassemble Oil Pump
start by:a) remove oil pump1. Remove the bolt and washer that hold the gear on the shaft. 2. Use tooling (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve.4. Remove the spring and bypass valve.5. Remove cover (2) from the pump body. 6. Use tooling (B) and remove the bearings from the cover. 7. Remove gears (5) from pump body (4).8. Use tooling (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use tooling (A) to install the bearings in the pump body. Install the bearings so the split in the bearings is 30° 15° from the center line of the oil pump outlet passage (2). 2. Install idler gear (1) and drive gear (3) in the oil pump body. Put clean engine oil on the bearings and the gears. 3. Use tooling (A) and install the bearings in cover (4). Install the bearings so the split in the bearings is 30° 15° from the center line of the bearing bores toward oil pump outlet passage (2).4. Install bypass valve (5), spring (6) and the retainer.5. Install the key on the shaft. 6. Install gear (7) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.end by:a) install oil pump