107691-2150 ZEXEL 9 400 619 565 BOSCH INJECTION-PUMP ASSEMBLY 9400619565 1076912150

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 565 9400619565

ZEXEL 107691-2150 1076912150

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Buy INJECTION-PUMP ASSEMBLY 107691-2150 zexel genuine, new aftermarket engine parts with delivery

Service parts 107691-2150 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-1180

3. GOVERNOR 105921-5303

4. SUPPLY PUMP 105237-6070

5. AUTOM. ADVANCE MECHANIS 105681-1090

6. COUPLING PLATE 105663-0760

7. COUPLING PLATE

8. _ 159590-3421

9. _

10. NOZZLE AND HOLDER ASSY 105118-5381

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3730

14. NOZZLE 105017-1221

15. NOZZLE SET

Include in #1:

107691-2150 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 565 9400619565

ZEXEL 107691-2150 1076912150

Zexel num

Bosch num

Firm num

Name

107691-2150
107691-2151

9 400 619 565

INJECTION-PUMP ASSEMBLY
* K 14CG TICS MD-TI6 TICS

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 131425-0520

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

PS/ACT control unit part no. 407910-3 03*

Selector switch no. 01

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 15

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 5.6 5.57 5.63

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 10.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 77 75.4 78.6

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 7.4+-0.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.8)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 77 76 78

Basic *

Fixing the lever *

Boost pressure kPa 48 48

Boost pressure mmHg 360 360

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.45

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 91.4 87.4 95.4

Fixing the lever *

Boost pressure kPa 48 48

Boost pressure mmHg 360 360

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_05

Adjusting point C

Rack position R3(R1-0. 9)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 37.1 33.1 41.1

Fixing the lever *

Boost pressure kPa 48 48

Boost pressure mmHg 360 360

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_06

Adjusting point D

Rack position R3-0.9

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 21 17 25

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R3-0.9

Boost pressure kPa 15.3 14 16.6

Boost pressure mmHg 115 105 125

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R3(R1-0. 9)

Boost pressure kPa 34.7 34.7 34.7

Boost pressure mmHg 260 260 260

Timer adjustment

Pump speed r/min 1070--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1020

Advance angle deg. 0 -0.5 0

Timer adjustment_03

Pump speed r/min 1080

Advance angle deg. -1.3 -1.8 -0.8

Remarks
Finish

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

_03

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

_04

CU407910-303* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_05

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

_06

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

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
----------
T1=G34 BCL=0.9+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=22deg+-5deg b=(38.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position) and confirm non-injection.
----------
aa=1670r/min bb=4.5-0.5mm
----------
a=15deg+-5deg b=38deg+-5deg

0000001301

(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)Pre-stroke: bb
----------
aa=6deg bb=5.6+-0.03mm
----------
a=(7deg)

0000001401

(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------

----------

0000001701

A : Stopper pin B: Connector
----------

----------

0000001801

C:Shim
----------

----------

0000001901

A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------

----------

0000002201 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=1500r/min Ra=R1(10.8)+1.45mm
----------

0000002301 SPEED SENSOR

(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1.0mm
----------

Information:

Install the new 291-5165 Bellows (10) to tube assembly (2) by placing the end of the bellows with the liner on the flange of the tube assembly. Secure bellows (10) to tube assembly (2) by using one new 202-1838 V Band Clamp (11). Refer to Illustration 7.
Illustration 8 g01794917
(12) 313-9428 Tube As
Install the flanged end of the new 313-9428 Tube As (12) to bellows (10) by using one new V-band clamp (11). Refer to Illustration 8.Note: Make sure that the tube assembly is temporarily supported so that the tube assembly axis lines up with the axis of the bellows before securing the tube assembly to the bellows. That way the weight of the tube is on the support and not on the bellows.
Illustration 9 g01794933
(13) 294-9631 Clamp As (14) 310-7675 Bracket (15) 5P-1076 Hard Washer (16) 8T-4183 Bolt
Install the bottom half of the new 294-9631 Clamp As (13) to the two new 310-7675 Brackets (14) by using two new 5P-1076