101602-2862 ZEXEL 9 400 610 579 BOSCH INJECTION-PUMP ASSEMBLY 9400610579 1016022862

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 579 9400610579

ZEXEL 101602-2862 1016022862

Service parts 101602-2862 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5501

3. GOVERNOR 105401-0881

4. SUPPLY PUMP 105210-5550

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105662-1280

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4100

11. Nozzle and Holder 23600-2710A

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

13. NOZZLE-HOLDER 105030-4440

14. NOZZLE 105015-9220

15. NOZZLE SET

Include in #1:

101602-2862 as INJECTION-PUMP ASSEMBLY

101603-8552 as _

Cross reference number

BOSCH 9 400 610 579 9400610579

ZEXEL 101602-2862 1016022862

Zexel num

Bosch num

Firm num

Name

101602-2862
101602-2863

9 400 610 579

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

Overflow valve 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 4.8 4.77 4.83

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 A

Rack position 10

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 116.5 115 118

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Boost pressure kPa 133 133

Boost pressure mmHg 1000 1000

Injection quantity adjustment_02

Adjusting point -

Rack position 6.8+-0.5

Pump speed r/min 480 480 480

Average injection quantity mm3/st. 10.5 9.5 11.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-1.8

Boost pressure kPa 66.7 64 69.4

Boost pressure mmHg 500 480 520

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(11.1)

Boost pressure kPa 120 120 120

Boost pressure mmHg 900 900 900

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)Boost compensator excessive fuel lever at operation (at 0 boost pressure): L1 (4)Boost compensator stroke: BCL (5)Rack difference between N = N1 and N = N2 (6)Set idle sub-spring
----------
K=6 L1=12.9+-0.1mm BCL=1.8+-0.1mm N1=750r/min N2=500r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Stopper bolt setting (3)When pump speed set at aa (4)Set the pump speed at bb (at delivery)
----------
aa=750r/min bb=900r/min
----------
a=5deg+-5deg b=18deg+-5deg c=3deg+-5deg