101605-9121 ZEXEL 9 400 615 369 BOSCH INJECTION-PUMP ASSEMBLY 9400615369 1016059121

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 369 9400615369

ZEXEL 101605-9121 1016059121

Service parts 101605-9121 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8501

3. GOVERNOR 105411-1661

4. SUPPLY PUMP 105220-5160

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-4720

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5762

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-3862

14. NOZZLE

105015-4190

15. NOZZLE SET

Include in #1:

101605-9121 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-6081 as _

104740-6082

Cross reference number

BOSCH 9 400 615 369 9400615369

ZEXEL 101605-9121 1016059121

Zexel num

Bosch num

Firm num

Name

101605-9121
101605-9122

9 400 615 369

DAEWOO

INJECTION-PUMP ASSEMBLY
DB58T * 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 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 1-5-3-6- 2-4

Pre-stroke mm 3.4 3.35 3.45

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 77 75.5 78.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 38.7 38.7

Boost pressure mmHg 290 290

Injection quantity adjustment_02

Adjusting point -

Rack position 6.6+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

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.

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 90 110

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 8.9

Boost pressure kPa 12 9.3 14.7

Boost pressure mmHg 90 70 110

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position (9.4)

Boost pressure kPa 25.3 18.6 32

Boost pressure mmHg 190 140 240

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)Main spring setting (5)Boost compensator stroke: BCL (6)Set idle sub-spring
----------
K=5 BCL=(0.5)+-0.1mm
----------

Speed control lever angle

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

----------
a=(1deg)+-5deg b=(19deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Speed = bb, rack position = cc (sealed at delivery)
----------
aa=40mm bb=0r/min cc=1-0.2mm
----------
a=44.5deg+-5deg b=(50deg)

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(90deg)