107691-2020 ZEXEL 9 400 610 270 BOSCH INJECTION-PUMP ASSEMBLY 9400610270 1076912020

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 270 9400610270

ZEXEL 107691-2020 1076912020

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 107691-2020 zexel genuine, new aftermarket engine parts with delivery

Service parts 107691-2020 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-1070

3. GOVERNOR 105921-5292

4. SUPPLY PUMP 105237-4140

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:

107691-2020 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 270 9400610270

ZEXEL 107691-2020 1076912020

Zexel num

Bosch num

Firm num

Name

107691-2020
107691-2021

9 400 610 270

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 131424-8520

Overflow valve opening pressure kPa 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

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 -13 13

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 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

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 setting
----------

----------
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.
----------
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=0.8~1mm
----------

Information:

2. Disconnect the fuel injection lines (2) from pump housing. Put plugs or caps in all lines and openings.3. Remove the three bolts that hold the fuel filter (3) to the aftercooler housing.4. Disconnect the sensing line (1) for the fuel ratio control from the aftercooler housing. 5. Disconnect the oil supply line (4) from the turbocharger.6. Remove the two water lines (5). 7. Disconnect the water outlet line (6) for the air compressor from the cylinder head.8. Remove the bolts (7) that fasten the cylinder head to the cylinder block. 9. Install 3/8"-16NC forged eyebolts in the cylinder head. Fasten a hoist and remove the cylinder head assembly. Weight of cylinder head assembly is 575 lb. (260 kg). Be sure to install a new gasket between the spacer plate and the cylinder block before installing the cylinder head assembly. See REMOVE and INSTALL SPACER PLATE in DISASSEMBLY AND ASSEMBLY.Install Cylinder Head Assembly
1. Clean the top surface of spacer plate and the surface it is in contact with on the cylinder head.2. Install the cylinder head gasket, water seals, and gasket on timing gear cover. 3. Install the 3/8"-16NC forged eyebolts in the cylinder head. Fasten a hoist and put the cylinder head assembly into position on the engine. Make sure the gear (1) in cylinder head is engaged with drive gear (2). 4. Put 9M3710 Anti-Seize Compound on the threads of the bolts for cylinder head. Install the bolts and washers. Tighten the bolts as follows: 1 -Tighten all bolts in number order to 135 lb.ft. (18.7 mkg).2 -Tighten all bolts in number order to 185 5 lb.ft. (25.6 0.7 mkg).3 -Tighten all bolts using hand torque only to 185 5 lb.ft. (25.6 0.7 mkg). 5. Install the two water lines (4).6. Connect the oil supply line (3) to the turbocharger.7. Connect the water outlet line (5) for the air compressor to the cylinder head. 8. Connect the sensing line (6) for the fuel ratio control to the aftercooler housing.9. Put the fuel filter in position, and install the three bolts.10. Remove the plugs and fuel injection lines and pumps. Connect the fuel injection lines (7) to the pumps. Tighten the nuts on fuel lines to 30 5 lb.ft. (4.1 0.7 mkg).11. Fill the cooling system with coolant.end by: a) install camshaft housingb) install fan drive