101401-7421 ZEXEL 9 400 611 145 BOSCH INJECTION-PUMP ASSEMBLY 9400611145 1014017421

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 145 9400611145

ZEXEL 101401-7421 1014017421

Service parts 101401-7421 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8681

3. GOVERNOR 105932-2370

4. SUPPLY PUMP 105210-6170

5. AUTOM. ADVANCE MECHANIS 105676-8040

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-7232

11. Nozzle and Holder 8-97115-503-1

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

13. NOZZLE-HOLDER 105048-3831

14. NOZZLE

15. NOZZLE SET 105019-1070

Include in #1:

101401-7421 as INJECTION-PUMP ASSEMBLY

106672-3660 as _

Cross reference number

BOSCH 9 400 611 145 9400611145

ZEXEL 101401-7421 1014017421

Zexel num

Bosch num

Firm num

Name

101401-7421
101401-7422

9 400 611 145

INJECTION-PUMP ASSEMBLY
* K 14BD PE4AD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 134424-3920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 3.8 3.75 3.85

Rack position
Point A R=A

Beginning of injection position
Governor 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 13.1

Pump speed r/min 1160 1160 1160

Average injection quantity mm3/st. 97 95.4 98.6

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.7+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 14.5 13.2 15.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.1)

Pump speed r/min 1160 1160 1160

Average injection quantity mm3/st. 97 96 98

Basic *

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.35

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 96.5 92.5 100.5

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_05

Adjusting point C

Rack position R2-0.45

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 86 82 90

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 95 95 127

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R2-0.45

Boost pressure kPa 27.3 26 28.6

Boost pressure mmHg 205 195 215

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R2(R1-0. 6)

Boost pressure kPa 46.7 46.7 46.7

Boost pressure mmHg 350 350 350

Timer adjustment

Pump speed r/min 1185--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1135

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1450

Advance angle deg. 4.8 4.3 5.3

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 5 4.5 5.5

Remarks
Measure the actual speed, stop

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=N23 BCL=0.45+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=42deg+-5deg b=32deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Stamping position on the A/T outer rim (4)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1. (5)B.T.D.C.: aa
----------
aa=7deg
----------
a=(60deg) b=(85deg)