106871-9035 ZEXEL 9 400 618 319 BOSCH INJECTION-PUMP ASSEMBLY 9400618319 1068719035

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 618 319 9400618319

ZEXEL 106871-9035 1068719035

Service parts 106871-9035 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5730

3. GOVERNOR 105306-1106

4. SUPPLY PUMP 105207-1140

5. AUTOM. ADVANCE MECHANIS 105636-1200

6. COUPLING PLATE 105663-0260

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7431

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7(180)/21.6(220)

13. NOZZLE-HOLDER 105030-4980

14. NOZZLE

105015-7310

15. NOZZLE SET

Include in #1:

106871-9035 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 319 9400618319

ZEXEL 106871-9035 1068719035

Zexel num

Bosch num

Firm num

Name

106871-9035

9 400 618 319

HYUNDAI

INJECTION-PUMP ASSEMBLY
8DC9 * 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 134424-1320

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 1-2-7-3- 4-5-6-8

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5

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

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point -

Rack position 8.8

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 97 94.1 99.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point F

Rack position 5.8+-0.5

Pump speed r/min 450 450 450

Each cylinder's injection qty mm3/st. 17 15.3 18.7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(8.8)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 97 96 98

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(8.8)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 105.7 101.5 109.9

Difference in delivery mm3/st. 8.4 8.4 8.4

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Remarks
(check)

Injection quantity adjustment_06

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 115 95 135

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_04

Pump speed r/min 1150

Advance angle deg. 6.5 6 7

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Rack limit using stop lever: RA (2)Excess fuel setting for starting: SXL (3)Damper spring setting: DL
----------
RA=11.6+-0.1mm SXL=(R1+0.9)+-0.1mm DL=4.3-0.2mm
----------

0000000901

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

----------
a=16deg+-3deg b=16deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, stopper bolt setting (2)Rack position bb
----------
aa=4-0.5mm bb=11.6+-0.1mm
----------
a=5deg+-6deg b=34deg+-6deg

0000001501 MICRO SWITCH

Switch adjustment Adjust the bolt so that the lower lever position is obtained when the switch is turned ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325+-25r/min Ra=5.6mm
----------