107691-2160 ZEXEL 9 400 619 614 BOSCH INJECTION-PUMP ASSEMBLY 9400619614 1076912160

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 614 9400619614

ZEXEL 107691-2160 1076912160

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Buy INJECTION-PUMP ASSEMBLY 107691-2160 zexel genuine, new aftermarket engine parts with delivery

Service parts 107691-2160 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-1180

3. GOVERNOR 105921-7240

4. SUPPLY PUMP 105237-6070

5. AUTOM. ADVANCE MECHANIS 105681-1090

6. COUPLING PLATE 105663-0760

7. COUPLING PLATE

8. _ 159590-7320

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:

107691-2160 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 614 9400619614

ZEXEL 107691-2160 1076912160

Zexel num

Bosch num

Firm num

Name

107691-2160
107691-2161

9 400 619 614

INJECTION-PUMP ASSEMBLY
* K

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. 407980-2 24*

Digi switch no. 14

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

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 7.5+-0.5

Pump speed r/min 670 670 670

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

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

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

Injection quantity adjustment_05

Adjusting point C

Rack position R2(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

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

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 24 23.5 24.5

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 24 23.5 24.5

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 24 23.5 24.5

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=24deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at speed = aa and rack position = bb and confirm non-injection. (2)Normal
----------
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

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

----------

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
----------

Information:

Table 4
Cat Specification for Neat (B100) Biodiesel Blending Fuel
Property Test Method, United States Test Method, International Units Limits, B100 Blending Fuel
Density at 15°C “ASTM D1298” “ISO 3675” g/cm3 0.86-0.90
Viscosity at 40°C “ASTM D445” “ISO 3104” mm2/s (cSt) 1.9-6.0
Flash Point “ASTM D93” “ISO 3679” °C 93 minimum
Pour Point - - - 6 °C (10 °F) minimum below ambient temperature
- Summer “ASTM D97” “ISO 3016” °C
- Winter
Cloud Point “ASTM D2500” °C Report
Sulfur Content(1) “ASTM D5453” “ISO 20846” “ISO 20884” percent weight 0.0015(2) maximum
Distillation - - - -
T90 “ASTM D86” “ISO 3924” °C 360
Cetane Number “ASTM D613” “ISO 5165” % evaporation 45 minimum
Sulfated Ash “ASTM D874” “ISO 3987” or "ISO 6245" percent weight 0.02 maximum
Water and Sediment “ASTM D2709” “ISO 12937” percent volume 0.05 maximum
Water "ASTM D1796" "EN ISO 12937" % m/m -
Copper Corrosion, 3 hours at 50oC “ASTM D130” “ISO 2160” - No. 1
Oxidation Stability “EN 14112” or "EN 15751" “EN 14112” or "EN 15751" hours 3 minimum
Ramsbottom Carbon Residue on 10% bottoms "ASTM D524" “ISO 10370” %-m/m 0.30 maximum
Carbon Residue, Conradson (CCR) “ASTM D4530” - percent weight 0.05 maximum
Esterification "ASTM D 7806" or "ASTM D 7371" “EN 14103” percent volume 97.5 minimum
Total Acid Number “ASTM D664” “EN 14104” mg KOH/g 0.5 maximum
Methanol Content “EN 14110” “EN 14110” percent weight 0.2 maximum
Monoglycerides “ASTM D6584” “EN 14105” percent weight 0.8 maximum
Diglycerides “ASTM D6584” “EN 14105” percent weight 0.2 maximum
Triglycerides “ASTM D6584” “EN 14105” percent weight 0.2 maximum
Free Glycerin “ASTM D6584” “EN 14105” percent weight 0.02 maximum
Total Glycerin “ASTM D6584” “EN 14105” percent weight 0.240 maximum
Phosphorus Content “ASTM D4951” “EN 14107” percent weight 0.001 maximum
Calcium plus Magnesium “EN 14538” “EN 14538” ppm 5 maximum
Sodium plus Potassium “EN 14538” “EN 14538” ppm 5 maximum
Cold Soak Filterability “ASTM D7501” – seconds 360 maximum
Cleanliness “ASTM D7619” “ISO 4406” – (3)
Total contamination "EN 12662" "EN 12662" mg/kg 24 maximum
Appearance "ASTM D4176" - - Clear and Bright
(1) Methods for testing S are based on the sulfur content in diesel fuel used for blending. Consult with the fuel supplier and ensure the correct method has been used
(2) Sulfur level must be per local regulations. Higher S levels may be used where allowed.
(3) Recommended cleanliness level for fuel as dispensed into the engine fuel tank is ISO 18/16/13 or cleaner per the test methods listed. Refer to the contamination control Chapter for more details.Note: Fuels that meet the most current revision level of "ASTM D6751" or "EN 14214" may be used for blending with an acceptable distillate fuel. The conditions, recommendations, and limits that are noted in this Biodiesel section apply.Referenced Documents
Refer to the “Reference Material - Fuel” section of this Special Publication for the reference material for the information in this section.