106671-5230 ZEXEL 9 400 619 861 BOSCH INJECTION-PUMP ASSEMBLY 9400619861 1066715230

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 861 9400619861

ZEXEL 106671-5230 1066715230

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Buy INJECTION-PUMP ASSEMBLY 106671-5230 zexel genuine, new aftermarket engine parts with delivery

Service parts 106671-5230 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-7690

3. GOVERNOR 105407-5200

4. SUPPLY PUMP 105237-4210

5. AUTOM. ADVANCE MECHANIS 105681-1250

6. COUPLING PLATE 105663-0650

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7940

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105030-4210

14. NOZZLE

105015-8410

15. NOZZLE SET

Include in #1:

106671-5230 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 861 9400619861

ZEXEL 106671-5230 1066715230

Zexel num

Bosch num

Firm num

Name

106671-5230
106671-5231

9 400 619 861

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 134424-0020

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 11.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 179.5 177.5 181.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 88 88

Boost pressure mmHg 660 660

Injection quantity adjustment_02

Adjusting point -

Rack position 6.3+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 14 13 15

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.

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 9.2

Boost pressure kPa 8 5.3 10.7

Boost pressure mmHg 60 40 80

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position (11.5)

Boost pressure kPa 74.6 67.9 81.3

Boost pressure mmHg 560 510 610

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 1 0.5 1.5

Remarks
Finish

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 (at 0 boost pressure): L1 (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting (7)Set the injection quantity changeover lever.
----------
K=12 L1=12.3+0.2mm BCL=(2.3)+-0.1mm
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Speed control lever angle

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

----------
a=(12deg)+-5deg b=(19deg)+-5deg

Stop lever angle

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

----------
a=26deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0.
----------
aa=12.3+0.2mm
----------
a=(14deg) b=(18deg)

0000001201

N:Normal (1)Rack position = aa (point D setting)
----------
aa=10.4mm
----------
a=44deg+-5deg b=(38deg)+-5deg

Timing setting

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

----------
a=(20deg)

Information:

Start By:a. disassemble governorb. remove fuel injection pumps 1. Remove the six lifters from the fuel pump housing.2. Remove rack (1) and camshaft (2) from the fuel pump housing. If necessary use a soft hammer to push the camshaft out the governor end. 3. Use tooling (A) and remove the three camshaft bearings from the fuel pump housing. 4. Remove rack bearing (4) and the other rack bearing from the fuel pump housing.5. Remove dowel (3) from the fuel pump housing. 6. Remove bolts (6), cover (5) and the gasket from the fuel pump housing.Assemble Fuel Injection Pump Housing
1. Install gasket (7) and cover (5) on the side of the fuel pump housing. 2. Use tooling (B) and install (D) shaped rack bearing into the automatic timing advance side of the fuel pump housing 87.0 0.5 mm (3.42 .02 in) from outside surface (X).3. The inside flat side diameter after assembly must be 11.178 0.050 mm (.440 .002 in) and the inside large diameter must be 12.767 0.058 mm (.503 .002 in). 4. Install dowel (3) in the fuel pump housing 6.0 0.5 mm (.24 .02 in) above the outside surface.5. Use tool group (C) and install the rack bearing into the fuel pump housing 7.16 0.13 mm (.282 .005 in) below the outside surface of the pump housing.6. The inside diameter of the bearing after assembly must be 12.746 0.045 mm (.502 .002 in). 7. Use tool group (A) and install the three camshaft bearings in the fuel pump housing with the oil holes in the bearings 30° 3° from the horizontal center line toward the plugged holes in the fuel pump housing.8. The inside diameter of all three bearings after assembly must be 68.339 0.038 mm (2.6905 .0015 in). 9. Make sure bearing (8) on automatic timing advance side is installed 1.0 0.5 mm (.04 .02 in) below surface (Y).10. Make sure middle bearing (9) is 218 0.3 mm (8.6 .01 in) below surface (Y). 11. Make sure bearing (10) governor side 1.00 0.25 mm (.04 .01 in) below the outside surface.12. Remove the plugs from the side of the fuel pump housing. The oil holes in the bearings must be in alignment with holes (11) in the fuel pump housing. If the bearings are not in alignment, remove them and install again. 13. Make an alignment of rack (1) and install it in the fuel pump housing.14. Install camshaft (2) in the fuel pump housing as shown.15. Install the six lifters in the fuel pump housing. Make sure the pins in the lifter are on the same side as the dowels in the fuel pump housing.End By:a. install fuel injection pumpsb. assemble governor