101401-2312 ZEXEL 9 400 611 493 BOSCH INJECTION-PUMP ASSEMBLY 9400611493 1014012312

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 493 9400611493

ZEXEL 101401-2312 1014012312

Service parts 101401-2312 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9830

3. GOVERNOR 105401-0691

4. SUPPLY PUMP 105220-6570

5. AUTOM. ADVANCE MECHANIS 105676-0931

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5221

11. Nozzle and Holder 23600-2601A

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105041-5171

14. NOZZLE 105015-6240

15. NOZZLE SET

Include in #1:

101401-2312 as INJECTION-PUMP ASSEMBLY

101603-2360 as _

Cross reference number

BOSCH 9 400 611 493 9400611493

ZEXEL 101401-2312 1014012312

Zexel num

Bosch num

Firm num

Name

101401-2312
101401-2313

9 400 611 493

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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 3.17 3.23

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point A

Rack position 12.8

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 115 113 117

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 78.6 78.6

Boost pressure mmHg 590 590

Injection quantity adjustment_02

Adjusting point C

Rack position 9+-0.5

Pump speed r/min 405 405 405

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 900 900 900

Rack position R1-1.85

Boost pressure kPa 16 13.3 18.7

Boost pressure mmHg 120 100 140

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Rack position R1(12.8)

Boost pressure kPa 65.3 58.6 72

Boost pressure mmHg 490 440 540

Timer adjustment

Pump speed r/min 1275--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1225

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min 1450

Advance angle deg. 3.25 2.95 3.55

Load 4/4

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)Set idle sub-spring (4)Main spring setting (5)Boost compensator stroke
----------
K=10
----------

Speed control lever angle

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

----------
a=10deg+-5deg b=26deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.2mm
----------
a=21deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)