101401-9161 ZEXEL 9 400 619 638 BOSCH INJECTION-PUMP ASSEMBLY 9400619638 1014019161


101401-9161 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 619 638 9400619638
ZEXEL 101401-9161 1014019161

Service parts 101401-9161 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101040-9871
3. GOVERNOR 105921-6060
4. SUPPLY PUMP 105210-5320
5. AUTOM. ADVANCE MECHANIS 105671-0300
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5481
11. Nozzle and Holder TM0113H50
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105048-3781
14. NOZZLE 105017-1360
15. NOZZLE SET

Include in #1:

101401-9161 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 638 9400619638
ZEXEL 101401-9161 1014019161


Zexel num
Bosch num
Firm num
Name
101401-9161 
101401-9162 
9 400 619 638 
   
INJECTION-PUMP ASSEMBLY
* K 14BC PE4A,5A, PE

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8140
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   131424-3420
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
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   12
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   69.4 68.9 69.9
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.   9.7 7.7 11.7
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(12)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   69.4 68.9 69.9
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.5
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   89.3 85.3 93.3
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.3
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   60.7 56.7 64.7
Fixing the lever   *
Timer adjustment
Pump speed r/min   850--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   800
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1475
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-9161
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=H04
----------

Speed control lever angle

Test data 101401-9161
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=20deg+-5deg b=(28deg)+-3deg

Stop lever angle

Test data 101401-9161
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=(24deg)+-5deg

0000001501 LEVER

Test data 101401-9161
CL:Center line of camshaft ST:Stop adjuster screw f1:Direction for pulling the speed lever f2:Direction for pulling the stop lever 1. Stop lever adjustment outline (1)After completing all adjustments, confirm that the lever angle is within the specifications in the normal position. (2)Set the speed lever in the full speed position. (3)At pump speed Na, position the rack at non-injection position Ra. (4)Set the stop adjusting screw to fix the speed lever in the idling position. (5)Confirm that there is no injection at pump speed Nb.
----------
Na=1550r/min Nb=325r/min Ra=7.2-0.5mm
----------

Timing setting

Test data 101401-9161
(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(150deg)




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