101441-9861 ZEXEL 9 400 619 646 BOSCH INJECTION-PUMP ASSEMBLY 9400619646 1014419861

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 646 9400619646

ZEXEL 101441-9861 1014419861

Service parts 101441-9861 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101044-8300

3. GOVERNOR 105410-9961

4. SUPPLY PUMP 105220-5740

5. AUTOM. ADVANCE MECHANIS 105622-1900

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105148-1121

11. Nozzle and Holder 1660043G03

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105078-0050

14. NOZZLE

105007-1130

15. NOZZLE SET

Include in #1:

101441-9861 as INJECTION-PUMP ASSEMBLY

106672-4712 as _

Cross reference number

BOSCH 9 400 619 646 9400619646

ZEXEL 101441-9861 1014419861

Zexel num

Bosch num

Firm num

Name

101441-9861
101441-9862

9 400 619 646

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

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 2.15 2.1 2.2

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 A

Rack position 12.1

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 45.5 44.5 46.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.9

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 45.1 43.6 46.6

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point -

Rack position 8.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 8 6.9 9.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 55 50 60

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 3.5 3 4

Timer adjustment_03

Pump speed r/min 1800

Advance angle deg. 6.6 6.1 7.1

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 7.3 7.3 7.3

Remarks
Measure the actual speed, stop

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)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=15
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Speed control lever angle

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

----------
a=36deg+-5deg b=31deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=12deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=7.6mm
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a1=A a2=B a3=C a4=- a5=- a6=- r1=1000r/min r2=1000r/min r3=1000r/min r4=- r5=- r6=- Q1=- Q2=45.5+-1mm3/st Q3=- Q4=- Q5=- Q6=- c1=- c2=+-4% c3=- c4=- c5=- c6=- a7=36 a8=35 a9=34 a10=33 a11=32 a12=31 a13=30 a14=29 a15=28 a16=27 a17=26 a18=25 a19=24 a20=23 a21=22 a22=21 a23=20 a24=- a25=- a26=- a27=- a28=- r7=1800r/min r8=1750r/min r9=1700r/min r10=1650r/min r11=1600r/min r12=1550r/min r13=1500r/min r14=1450r/min r15=1400r/min r16=1350r/min r17=1300r/min r18=1250r/min r19=1200r/min r20=1150r/min r21=1100r/min r22=1050r/min r23=1000r/min r24=- r25=- r26=- r27=- r28=- R7=1935+-45r/min R8=1880+-43r/min R9=1825+-42r/min R10=1770+-41r/min R11=1720+-40r/min R12=1665+-38r/min R13=1610+-37r/min R14=1555+-36r/min R15=1505+-35r/min R16=1450+-33r/min R17=1395+-32r/min R18=1340+-31r/min R19=1290+-30r/min R20=1235+-28r/min R21=1180+-27r/min R22=1130+-26r/min R23=1075+-25r/min R24=- R25=- R26=- R27=- R28=-

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(100deg)