101401-1580 ZEXEL 9 400 613 490 BOSCH INJECTION-PUMP ASSEMBLY 9400613490 1014011580


101401-1580 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 490 9400613490
ZEXEL 101401-1580 1014011580

Service parts 101401-1580 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101040-9800
3. GOVERNOR 105921-5710
4. SUPPLY PUMP 105220-6050
5. AUTOM. ADVANCE MECHANIS 105676-0810
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-4461
11. Nozzle and Holder ME016315
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105048-3211
14. NOZZLE 105017-0360
15. NOZZLE SET

Include in #1:

101401-1580 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 490 9400613490
ZEXEL 101401-1580 1014011580


Zexel num
Bosch num
Firm num
Name
101401-1580 
101401-1581 
9 400 613 490 
   
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   6-2-600
Overflow valve   131424-8720
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   1-3-4-2
Pre-stroke mm   3.2 3.15 3.25
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-3
deg.   90 89.5 90.5
Difference between angles 2
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 3
Cyl.1-2
deg.   270 269.5 270.5
Injection quantity adjustment
Adjusting point   -
Rack position   11
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   75.5 73.9 77.1
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   H
Rack position   9.5+-0.5
Pump speed r/min   325 325 325
Average injection quantity mm3/st.   14.8 13.5 16.1
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   75.5 74.5 76.5
Basic   *
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1.3
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   96.2 92.2 100.2
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2(R1-0. 6)
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   47.8 43.8 51.8
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
Injection quantity adjustment_06
Adjusting point   D
Rack position   R2-0.4
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   33.2 29.2 37.2
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   400 400 400
Rack position   R2-0.4
Boost pressure kPa   6.7 5.4 8
Boost pressure mmHg   50 40 60
Boost compensator adjustment_02
Pump speed r/min   400 400 400
Rack position   R2(R1-0. 6)
Boost pressure kPa   23.3 23.3 23.3
Boost pressure mmHg   175 175 175
Timer adjustment
Pump speed r/min   1250--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1200
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1600
Advance angle deg.   4.5 4 5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-1580
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=G57 BCL=0.4+-0.1mm
----------

Speed control lever angle

Test data 101401-1580
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=(38deg)+-3deg

Stop lever angle

Test data 101401-1580
N:Engine manufacturer's normal use S:Stop the pump. (1)Use the hole at R = aa (2)Free (at delivery) (3)Rack position corresponding to bb (4)Set the stopper bolt at speed = cc and rack position = dd (non-injection rack position). Confirm non-injection. (5)After setting the stopper bolt, confirm non-injection at speed ee. Rack position = ff or less (non-injection rack position).
----------
aa=40mm bb=16mm cc=1700r/min dd=6.6-0.5mm ee=325r/min ff=8mm
----------
a=26.5deg+-5deg b=16deg+-5deg c=33deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=1025r/min Ra=8.5+-0.1mm
----------

Timing setting

Test data 101401-1580
(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11.5deg
----------
a=(130deg)




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