101601-5091 ZEXEL 9 400 619 588 BOSCH INJECTION-PUMP ASSEMBLY 9400619588 1016015091

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 588 9400619588

ZEXEL 101601-5091 1016015091

Service parts 101601-5091 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9891

3. GOVERNOR 105921-1371

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0220

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4292

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105025-0490

15. NOZZLE SET

Include in #1:

101601-5091 as INJECTION-PUMP ASSEMBLY

106682-4710 as _

Cross reference number

BOSCH 9 400 619 588 9400619588

ZEXEL 101601-5091 1016015091

Zexel num

Bosch num

Firm num

Name

101601-5091
101601-5092

9 400 619 588

INJECTION-PUMP ASSEMBLY
* K 14BE PE6A 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 131424-5720

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 1-4-2-6- 3-5

Pre-stroke mm 3.1 3.07 3.13

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 8.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 46.6 44.6 48.6

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 8+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 8 6.5 9.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(8.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 46.6 45.6 47.6

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 45.2 43.2 47.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.2

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 52 50 54

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.15

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 38 36 40

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position 13.5+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 95 105

Fixing the lever *

Rack limit *

Injection quantity adjustment_08

Adjusting point E

Rack position R1+0.35

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 28 24 32

Fixing the lever *

Timer adjustment

Pump speed r/min 1300+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 3.5 3.2 3.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
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T1=A76
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Speed control lever angle

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

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a=33deg+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=40deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
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N1=1000r/min L1=(1.5)mm L2=7+-0.5mm h1=-
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Ra=R1(8.7)mm Rb=(7.8)mm Pa=(84.5)kPa((634)mmHg) Pb=61.6kPa(462mmHg) Q1=46.6+-1cm3/1000st Q2=32.6+-1cm3/1000st

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
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a=(70deg)