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


101441-9861 INJECTION-PUMP ASSEMBLY
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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

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

Test data 101441-9861
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
----------

Speed control lever angle

Test data 101441-9861
F:Full speed I:Idle (1)Stopper bolt setting
----------

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

Stop lever angle

Test data 101441-9861
N:Pump normal S:Stop the pump.
----------

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

0000001501 GOV FULL LOAD ADJUSTMENT

Test data 101441-9861
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
----------
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

Test data 101441-9861
(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)




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