106671-5081 ZEXEL 9 400 619 691 BOSCH INJECTION-PUMP ASSEMBLY 9400619691 1066715081

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 691 9400619691

ZEXEL 106671-5081 1066715081

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Buy INJECTION-PUMP ASSEMBLY 106671-5081 zexel genuine, new aftermarket engine parts with delivery

Service parts 106671-5081 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-7220

3. GOVERNOR 105487-5290

4. SUPPLY PUMP 105217-1750

5. AUTOM. ADVANCE MECHANIS 105636-2160

6. COUPLING PLATE 105663-0650

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7030

11. Nozzle and Holder 1660096573

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.6{230}.

13. NOZZLE-HOLDER 105030-4210

14. NOZZLE 105015-8540

15. NOZZLE SET

Include in #1:

106671-5081 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 691 9400619691

ZEXEL 106671-5081 1066715081

Zexel num

Bosch num

Firm num

Name

106671-5081
106671-5082

9 400 619 691

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 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 1-4-2-6- 3-5

Pre-stroke mm 3.9 3.85 3.95

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10.3

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 163.2 161.2 165.2

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_02

Adjusting point -

Rack position 5.7+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 16 15 17

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position 9.05

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 129.1 125.1 133.1

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position 9.05

Boost pressure kPa 3.3 3.3 5.3

Boost pressure mmHg 25 25 40

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 10.65

Boost pressure kPa 22.7 16 29.4

Boost pressure mmHg 170 120 220

Timer adjustment

Pump speed r/min 1000--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 950

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 1.5 1 2

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Variable speed specification. (5)Boost compensator stroke (6)Rack limit using stop lever (7)Set idle sub-spring (with the lever free). (8)Damper spring setting (9)Perform governor adjustment at an ambient temperature of at least 15 deg C (boost compensator start spring is shape memory alloy).
----------
RT=1 TH=2.4mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=21deg+-5deg b=16deg+-5deg

0000000901

F:Full load (1)Fix the lever.
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----------
a=24deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Use the hole at R = bb
----------
aa=10.65mm bb=25mm
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a=11deg+-5deg b=30.5deg+-5deg

0000001501 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)
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N1=600r/min Ra=10.3mm
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Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)Secondary timing stamping position for the No. 1 cylinder's beginning of injection (5)Pump vertical direction (6)Direction of rotation (7)Pointer (8)Timing device stamping (9)Pointer stamping (10)Timing device (11)Move b deg and stamp both at the same time as shown above. (12)Outside circumference of timing device
----------

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a=(30deg) b=1deg30min

Information:

1. Remove oil filter element (1). 2. Remove two bolts (4).3. Remove four bolts (3).4. Remove six bolts (2). Remove oil filter base, gaskets and O-rings. The following steps are for the installation of the oil filter and oil filter base. Position gaskets and install all bolts finger tight before tightening to the standard torque.5. Be sure the O-rings are in place on oil filter base. Position gaskets and oil filter base. Install six bolts (2).6. Install four bolts (3).7. Position gasket. Install two bolts (4). Tighten all the bolts to standard torque.8. Install oil filter element (1).Disassemble & Assemble Oil Filter Base
Start By:a. remove oil filter base 1. Remove the O-rings. Remove bolt (1). 2. Remove relief valve group (2). 3. Remove four bolts and remove covers (3). Remove oil cooler by-pass valve (5), oil cooler by-pass valve spring (4) and spool (6). 4. Remove plug (7). Remove oil filter by-pass valve (8). The following steps are for the assembly of the oil filter base.5. Install by-pass valve (8) and plug (7).6. Install oil cooler by-pass valve (5), oil pump by-pass valve (6) and spring (4). Position covers (3). Install four bolts.7. Position relief valve group (2). Install bolt (1). Install O-ring seals.End By:a. install oil filter base