101605-9830 ZEXEL 9 400 615 392 BOSCH INJECTION-PUMP ASSEMBLY 9400615392 1016059830

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 392 9400615392

ZEXEL 101605-9830 1016059830

Service parts 101605-9830 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8220

3. GOVERNOR 105411-1990

4. SUPPLY PUMP 105220-6280

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-6620

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101401-4981 as _

101605-9830 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 392 9400615392

ZEXEL 101605-9830 1016059830

Zexel num

Bosch num

Firm num

Name

101605-9830

9 400 615 392

DAEWOO

INJECTION-PUMP ASSEMBLY
DB58TI K 14BF INJECTION PUMP ASSY PE6AD 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 131424-1520

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 3.8 3.75 3.85

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 9.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 95 93.5 96.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 52.7 52.7

Boost pressure mmHg 395 395

Injection quantity adjustment_02

Adjusting point -

Rack position 6.7+-0.5

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 19.5 18.2 20.8

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. 75 75 95

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 R1-0.75

Boost pressure kPa 20 17.3 22.7

Boost pressure mmHg 150 130 170

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(9.7)

Boost pressure kPa 39.3 32.6 46

Boost pressure mmHg 295 245 345

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 (6)Boost compensator stroke: BCL
----------
K=8 BCL=0.75+-0.1mm
----------

Speed control lever angle

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

----------
a=4deg+-5deg b=17deg+-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=1-0.5mm
----------
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=13deg
----------
a=(100deg)