101602-2990 ZEXEL 9 400 619 985 BOSCH INJECTION-PUMP ASSEMBLY 9400619985 1016022990

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 985 9400619985

ZEXEL 101602-2990 1016022990

Service parts 101602-2990 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9940

3. GOVERNOR 105400-8540

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-8820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5161

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-8241

15. NOZZLE SET

Include in #1:

101401-4951 as _

101602-2990 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 985 9400619985

ZEXEL 101602-2990 1016022990

Zexel num

Bosch num

Firm num

Name

101602-2990
101602-2991

9 400 619 985

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 3.45 3.42 3.48

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 11

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 69 67 71

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.5+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 90 100

Fixing the lever *

Rack limit *

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=6
----------

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.
----------
aa=750r/min bb=900r/min
----------
a=5deg+-5deg b=18deg+-5deg c=2deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position aa or less, pump speed bb
----------
aa=7mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

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

----------
a=(70deg)