106492-4000 ZEXEL 9 400 619 856 BOSCH INJECTION-PUMP ASSEMBLY 9400619856 1064924000 12644351010

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 856 9400619856

ZEXEL 106492-4000 1064924000

YANMAR 12644351010 12644351010

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Buy INJECTION-PUMP ASSEMBLY 106492-4000 zexel genuine, new aftermarket engine parts with delivery

Service parts 106492-4000 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106049-5000

3. GOVERNOR 105407-6880

4. SUPPLY PUMP 105217-1590

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105663-0960

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

106492-4000 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 856 9400619856

ZEXEL 106492-4000 1064924000

YANMAR 12644351010 12644351010

Zexel num

Bosch num

Firm num

Name

106492-4000
106492-4001

9 400 619 856

12644351010 YANMAR

INJECTION-PUMP ASSEMBLY
4HAL2-TN * K 14BW PE4P,4PD PE

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 131424-1520

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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-4-3

Pre-stroke mm 2.9 2.85 2.95

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 10.2

Pump speed r/min 600 600 600

Each cylinder's injection qty mm3/st. 157.5 152.8 162.2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 5.6+-0.5

Pump speed r/min 350 350 350

Each cylinder's injection qty mm3/st. 18.5 15.7 21.3

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 205 195 215

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=35deg+-3deg b=(11deg)+-5deg c=(11deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

2. Turn the crankshaft until two pistons are at bottom center.3. Remove bolts (1) and the bearing caps. Push the rods and pistons up until the rings are out of the cylinder liners. 4. Remove pistons (2) and connecting rods from the cylinder liners.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.Install Pistons & Connecting Rod Assemblies
1. Put clean engine oil on piston rings, connecting rod bearings and cylinder liners. 2. Use Tool (A), and install piston (2) and the connecting rod in the cylinder liner.3. Install the bearing cap on the connecting rod with the number on the side of the bearing cap on the same side and same number as on the connecting rod.4. Put 2P2506 Thread Lubricant on the threads of the bolts. Install the nuts, and tighten them to a torque of 90 8 N m (67 6 lb ft). Put a mark on the nuts and cap, and tighten the nuts an extra 90 5 degrees.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.End By:a. install piston cooling tubesb. install oil pumpc. install cylinder head assemblyDisassemble & Assemble Pistons & Connecting Rod Assemblies
Start By:a. remove pistons and connecting rod assemblies 1. Remove bearings (3) from the connecting rod and connecting rod cap.2. Remove retainer ring (1) with Tool (A).3. Remove pin (2) and connecting rod (4) from the piston. 4. Remove piston rings (5) from the piston with Tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See, Use Of Piston Bearing Removal And Installation Tools, Special Instructions, SMHS7295.5. Heat connecting rod (4) in an oven to a temperature of 177° to 260°C (350° to 500° F). Never use a direct flame to heat a connecting rod. 6. Put connecting rod (4) in position on the base plate of Tool (C). Put a new rod pin bearing (6) on the adapter part of Tool (C). The old bearing is pushed out by Tool (C) as the new bearing is installed.7. Use Tool (C) to push the new bearing into the connecting rod until the push adapter of Tool (C) makes full contact with the connecting rod surface.8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 50.830 0.008 mm (2.0012 .0003 in).9. Check the clearance between the ends of the piston rings. See the topic, "Pistons & Rings" in Specifications Manual, SENR6470.10. Install the oil ring spring in the oil ring groove of the piston. The oil ring is to be installed over the spring with the oil ring end gap 180° from the oil ring spring joint.11. Install the oil ring on the piston with tool (B).12. Install the second (intermediate) piston ring with the side that has the identification "UP-2" toward the top of the piston. Use Tool (B) to install